Associate Director – External Manufacturing

1. Role Purpose

To lead and manage External Manufacturing (EM) operations by ensuring successful technology transfer, process scale-up, manufacturing readiness, commercial production execution, process optimization, and cost-effective operations at toll manufacturing locations. The role acts as the key interface between R&D, Technology & Development (T&D), Supply Chain, Quality, EHS, and EM partners to ensure seamless product commercialization and reliable supply while maintaining safety, quality, delivery, and cost objectives.

2.

Key Responsibilities
1. External Manufacturing Strategy & Planning
Develop and execute External Manufacturing (EM) plans in consultation with business and functional stakeholders.
Identify manufacturing capacities and capabilities available at toll manufacturing partners.
Support sourcing and evaluation of potential External Manufacturing partners.
Drive commercialization and scale-up projects through a structured execution framework.
Monitor production plans and align output with business demand forecasts.
Ensure optimum utilization of approved EM capacities.

2. Process Engineering & Technology Transfer
Engineering Documentation
Prepare, review, and approve:
Block Flow Diagrams (BFD)
Process Flow Diagrams (PFD)
Piping & Instrumentation Diagrams (P&)
Process Datasheets
Utility Requirement Specifications
Equipment Lists
Ensure process engineering documentation complies with company standards.
Review process modifications and maintain engineering document control.

Technology Transfer
Witness demonstration batches at R&D and Pilot Plant facilities.
Understand reaction chemistry, critical process parameters, process hazards, and operating windows.
Lead technology transfer from laboratory/pilot scale to commercial manufacturing.
Independently implement and commercialize products at EM sites.
Ensure successful execution of first-time commercial batches.

3. Material & Energy Balance Management
Prepare detailed material balance and energy balance calculations.
Establish raw material consumption norms for products.
Determine utility requirements including (If required. As per current practice for existing product, Operation/T&D has to provide):
Steam
Chilling Water
Cooling Water
Electricity
Nitrogen
Compressed Air
Monitor actual consumption against design assumptions.
Analyze deviations and implement improvement actions.
Establish mass balance monitoring systems across manufacturing campaigns.

4. External Manufacturing Facility Assessment
Conduct technical assessments of External Manufacturing facilities.
Evaluate facility capabilities including:
Reactor Sizing
Distillation Systems
Utility Infrastructure
Storage Facilities
Material Handling Systems
Process Control Systems
Verify suitability of equipment for intended processes.
Assess manufacturing readiness before commercialization.
Conduct periodic technical audits of EM facilities.

5. Site Readiness & Commissioning
Coordinate with EM partners for readiness of equipment, manpower, utilities, and raw materials.
Conduct pre-commissioning inspections and readiness reviews.
Verify completion of engineering, safety, and operational requirements.
Lead commissioning and start-up of commercial campaigns.
Ensure smooth scale-up from pilot batch to commercial production.
Support EM production teams during initial manufacturing campaigns.

6. Production Campaign Management
Manage end-to-end manufacturing campaigns at toll manufacturing locations.
Prepare batch execution plans and campaign schedules.
Monitor:
Production Progress
Campaign Timelines
Batch Performance
Yield Achievement
Resource Utilization
Manufacturing Efficiency
Track batch-wise production data and identify deviations.
Publish weekly manufacturing reports and campaign performance updates.
Prepare campaign closure reports and lessons learned documentation.

7. Process Optimization & Troubleshooting
Provide technical troubleshooting support for ongoing manufacturing operations.
Coordinate with R&D and T&D teams to resolve process challenges.
Perform root cause analysis for:
Yield Losses
Process Deviations
Quality Issues
Production Interruptions
Identify opportunities for:
Yield Improvement
Utility Reduction
Throughput Enhancement
Cycle Time Reduction
Lead process optimization projects and continuous improvement initiatives.

8. Yield, Cost & Performance Management
Monitor manufacturing economics and process efficiencies.
Analyze:
Product Yield
Raw Material Consumption
Solvent Recovery
Utility Consumption
Conversion Cost
Establish and monitor manufacturing performance benchmarks.
Develop…