About this role
Job Purpose
To lead and manage instrumentation maintenance, reliability, automation and control-system activities across the API manufacturing facility, ensuring safe, reliable and compliant operation of process and utility systems.
Key Responsibilities
Lead preventive, predictive and breakdown maintenance of instrumentation and control systems.
Ensure reliable operation of field instruments including pressure, temperature, flow, level, pH, conductivity and analytical instruments.
Manage maintenance and troubleshooting of control valves, on/off valves, actuators, positioners, transmitters, switches and sensors.
Handle PLC, DCS, SCADA, ESD and related automation systems.
Plan and execute preventive-maintenance schedules for critical instrumentation and automation equipment.
Troubleshoot instrument failures and minimize production downtime.
Ensure proper calibration, verification and maintenance of critical instruments as per approved procedures and schedules.
Review calibration reports, instrument history, maintenance records and related GMP documentation.
Support instrumentation qualification, commissioning and validation activities for new and modified equipment.
Coordinate with Production, QA, QC, Electrical, Mechanical and Project teams for plant activities.
Support change control, deviation, CAPA, OOS-related technical investigations and RCA where instrumentation is involved.
Ensure compliance with GMP, GEP, SOPs, data integrity and EHS requirements.
Maintain documentation related to calibration, breakdowns, preventive maintenance, modifications and instrument history.
Supervise instrumentation engineers, technicians and contractors and allocate maintenance activities.
Plan manpower, spares, instruments, tools and service requirements for instrumentation maintenance.
Coordinate with OEMs and external agencies for specialized maintenance, calibration and troubleshooting.
Review instrumentation spare requirements and maintain adequate inventory of critical spares.
Participate in plant shutdown, turnaround and maintenance planning.
Identify opportunities for automation, instrumentation reliability improvement and energy/process optimization.
Ensure proper implementation of permit-to-work, LOTO and electrical/instrumentation safety practices.
Key Instrumentation Exposure
DCS / PLC / SCADA systems
ESD / safety-instrumented systems
Pressure, temperature, flow and level transmitters
pH and conductivity instruments
Control valves and positioners
Pneumatic control systems
VFD and motor-control interfaces
Online process analyzers
Weighing systems / load cells
Batch control systems
Field instruments and control panels
API Plant Exposure
Experience with instrumentation of:
Reactors and agitator systems
Distillation systems
Solvent recovery systems
Centrifuges and dryers
Vacuum systems
Heat exchangers
Storage tanks
Utility systems
Chillers and cooling towers
Boilers / thermic-fluid systems
Compressed-air systems
Qualification
B.E./B.Tech. in Instrumentation & Control / Electronics & Instrumentation / Electronics Engineering
Diploma holders with extensive relevant experience may also be considered.
Experience
8–12 years of relevant experience in API / pharmaceutical / chemical manufacturing, with strong exposure to instrumentation maintenance and automation.
Key Competencies
Instrumentation maintenance and troubleshooting
DCS/PLC/SCADA knowledge
Calibration and qualification
Control-valve troubleshooting
Preventive and predictive maintenance
RCA, deviation and CAPA
GMP/GEP documentation
Project and shutdown management
Vendor and contractor management
Team leadership
Spare-parts planning
Safety and compliance