Senior Manager – Digitalization & Automation

Manager / Senior Manager – Digitalization & Automation Department: Engineering Location: Chennai Industry: Active Pharmaceutical Ingredients (API) Manufacturing Reporting To: Head – Engineering Position Summary The Manager/Senior Manager – Digitalization & Automation will lead the digital transformation journey across API manufacturing operations by implementing Industry 4.0 technologies, advanced automation systems, and smart manufacturing solutions. The role is responsible for driving operational excellence through the adoption of digital technologies that enhance productivity, improve quality, ensure regulatory compliance, optimize asset utilization, and support sustainable manufacturing practices. The incumbent will work collaboratively with Manufacturing, Engineering, Quality, IT, Maintenance, Supply Chain, EHS, and Corporate Digital teams to design, implement, and scale digital solutions across manufacturing facilities while ensuring compliance with cGMP, Data Integrity, and global regulatory standards.

Key Responsibilities 1. Digital Transformation Strategy Develop and execute the organization's Digital Manufacturing and Industry 4.0 roadmap aligned with business objectives. Assess plant digital maturity and identify opportunities for digital transformation.

Lead enterprise-wide digitalization initiatives across manufacturing operations. Drive the transition from conventional manufacturing to smart, connected, and data-driven operations. 2. Automation & Smart Manufacturing Lead the implementation of automation solutions including: PLC, SCADA, DCS and HMI systems Batch Automation Automated Material Handling Systems Develop User Requirement Specifications (URS), Functional Design Specifications (FDS), and oversee system design, installation, commissioning, qualification, and validation. 3.

Manufacturing Digitalization Drive implementation of digital manufacturing solutions such as: Manufacturing Execution Systems (MES) Electronic Batch Records (EBR) Digital SOPs Electronic Logbooks Paperless Manufacturing Digital Shift Reports Digital Checklists Real-time Production Monitoring Digital Workflows Process Historians 4. Industry 4.0 Implementation Develop and implement scalable Industry 4.0 initiatives by: Connecting manufacturing equipment through Industrial Internet of Things. Enabling real-time monitoring of production processes.

Implementing predictive maintenance using machine learning and sensor data. Deploying smart manufacturing dashboards. Utilizing AI and advanced analytics for process optimization.

Exploring Digital Twin technologies for process simulation and optimization. Standardizing digital solutions for deployment across multiple manufacturing plants. Training of the team for use of AI 5.

Data Analytics & Business Intelligence Develop production dashboards using Power BI, Tableau, SQL, or equivalent analytics tools. Monitor KPIs including: Overall Equipment Effectiveness (OEE) Equipment Availability Production Throughput Yield Cycle Time Energy Consumption Downtime Batch Performance Asset Utilization Support data-driven decision-making through advanced analytics. 6. Predictive & Preventive Maintenance Implement IIoT-enabled predictive maintenance programs.

Develop condition monitoring systems for critical equipment. Reduce unplanned downtime through predictive analytics. Integrate predictive maintenance with CMMS platforms. 7.

System Integration Integrate manufacturing systems with enterprise platforms including: ERP (SAP) Laboratory Information Management System (LIMS) Quality Management System (QMS) Computerized Maintenance Management System (CMMS) Historian Systems 8. Mechanize and Automate : Physical Operations through Automatic or Mechanised transfer, transport systems. Create SOPs to reduce duplication of work which can lead to reduction of manpower.

Create Simple systems for operations, training, and documentation. Digital allocation of manpower to manufacturing blocks through skill mapping, leading more efficient use of manpower and reduction of overtime. Ensure seamless information flow across manufacturing operations.

Qualifications Bachelor's Degree (B.E./B.Tech) in: Instrumentation Engineering Electrical Engineering Electronics & Communication Engineering Automation & Control Engineering Chemical Engineering Mechanical Engineering (with automation experience) Computer Science / Information Technology (with manufacturing experience) Experience 10–15 years of experience in pharmaceutical, API, specialty chemical, or process manufacturing industries. Minimum 5 years of experience leading digitalization and automation initiatives. Key Performance Indicators (KPIs) Successful implementation of digital transformation projects.

Improvement in Overall Equipment Effectiveness (OEE). Increase in manufacturing throughput. Reduction in production cycle time.

Improvement in batch yield and right-first-time performance. Reduction in manual interventions and paper-based documentation. Reduction in equipment downtime through predictive maintenance.

Improvement in asset utilization. Energy and utility savings. Compliance with Data Integrity and regulatory requirements.

Adoption rate of digital manufacturing systems. Return on Investment (ROI) from automation initiatives.