Executive

Job Information
Designation: Executive – Automation & Instrumentation
Department: Engineering / Instrumentation & Automation
Industry: Pharmaceutical API Manufacturing
Reporting To: Engineering Manager / Instrumentation Manager / Head of Engineering
Location: Manufacturing Plant
Experience: Typically 3–5 years, depending on plant requirements
Qualification: Diploma / B.E. / B.Tech in Instrumentation, Electronics, Electrical, or Automation Engineering
2. Job Purpose
To ensure reliable operation, maintenance, troubleshooting, calibration, and optimization of PLC, SCADA, DCS, and industrial instrumentation systems in an API manufacturing facility.

The role is responsible for maintaining automation systems associated with process equipment, reactors, pumps, compressors, HVAC, chillers, refrigeration, utilities, and other plant equipment. It also supports preventive maintenance, breakdown maintenance, control-system modifications, process safety, data integrity, and compliance with applicable pharmaceutical quality requirements.

3. Key Responsibilities
A. PLC System Operation and Maintenance
Operate, maintain, and troubleshoot PLC-based automation systems.
Work with PLC platforms such as Siemens, Allen-Bradley, Mitsubishi, Schneider, or other installed systems.
Monitor PLC CPU status, input/output modules, communication networks, and field signals.
Troubleshoot digital and analog inputs and outputs, including 4–20 mA signals.
Diagnose PLC hardware faults, communication errors, sensor failures, and interlock problems.
Support PLC program backup, restoration, version control, and approved modifications.
Coordinate with OEMs and automation vendors for major PLC faults and system upgrades.
Verify the correct operation of sequence logic, permissives, alarms, and equipment interlocks.
Maintain PLC hardware, software, and configuration documentation.
B. SCADA System Management
Monitor plant operations through SCADA systems and operator interfaces.
Maintain SCADA communication with PLCs, remote I/O, field instruments, and plant equipment.
Troubleshoot communication failures, alarm issues, tag errors, and operator-interface problems.
Verify process trends, alarm histories, event logs, and equipment status indications.
Support the configuration of process graphics, tags, alarm limits, and trend displays through approved change procedures.
Ensure that operator screens accurately represent field conditions.
Coordinate SCADA software backups, restoration tests, and system maintenance.
Support authorized user access, audit trails, and electronic records where applicable.
C. DCS Operation and Maintenance
Monitor and maintain Distributed Control System (DCS) hardware and control functions.
Support DCS controllers, operator stations, engineering stations, communication networks, and I/O systems.
Troubleshoot process control loops, controller faults, communication errors, and field signal abnormalities.
Monitor PID control loops and assist in tuning under approved engineering procedures.
Verify sequence controls, permissives, trips, alarms, and process interlocks.
Coordinate with process engineering and production teams to resolve control-system issues.
Maintain DCS configuration backups and approved control-system documentation.
Support system expansion, hardware replacement, and software upgrades.
Ensure that changes to control logic are reviewed, approved, tested, and documented.
D. Instrumentation Maintenance and Calibration
Maintain and calibrate instruments used in API manufacturing processes.
Handle instruments such as:
Temperature transmitters and RTDs
Pressure transmitters and pressure switches
Differential pressure transmitters
Flow meters and flow transmitters
Level transmitters and level switches
pH, conductivity, and other process analyzers where installed
Control valves, positioners, and actuators
Load cells and weighing systems where applicable
Perform calibration using approved procedures and suitable reference standards.
Verify instrument ranges, zero and span, accuracy, and output signals.
Troubleshoot instrument failures, signal fluctuations, drift, and wiring faults.
Maintain calibration schedules, certificates, and instrument history records.
Coordinate calibration of critical instruments with quality assurance and metrology teams.
Investigate out-of-tolerance instruments and assess potential impact on affected processes where required.
E. API Process Equipment Automation
Support automation systems used in reactors, storage tanks, heat exchangers, centrifuges, dryers, condensers, and associated equipment.
Monitor temperature, pressure, level, flow, agitation, and other process parameters.
Verify automated sequences, batch steps, equipment permissives, and process alarms.