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Manager, Process Engineering (SME - Injectable Packaging: Vial, PFS, Bag, Cartridge)

Amneal Pharmaceuticals • Full-time • Ahmedabad, IN • 3w ago

Key Responsibilities

JOB DESCRIPTION

Process Design & Optimization
Lead the technical development, configuration, and optimization of injectable packaging lines for:
- Glass/Plastic Vials (liquid/freeze-dried)
- Pre-Filled Syringes (manual, semi-automatic, and fully automated lines)
- IV Bags (PVC/Non-PVC)
- Drug Delivery Cartridges (pens, auto-injectors)
Review and provide support to validate key process parameters (e.g., accuracy, line speed, container closure integrity, reject rates).
Collaborate with equipment vendors and cross-functional teams for Installation, Commissioning and Troubleshooting to ensure process suitability and compliance.
Operational Excellence, Maintenance & Troubleshooting
Responsible for supervision and monitoring of day-to-day site activities from a process engineering perspective, ensuring stringent adherence to quality, cGMP regulations, and safety norms related to process operations. Proactively engage in troubleshooting and resolution of on-site process-related challenges and deviations.
Responsible for Troubleshooting of issues, periodic health check-up of Process Equipment and effective preventive maintenance across various Amneal plant.
To take necessary steps for reduction of equipment breakdown and ensure that certain KPIs such as Mean Time Between Failure (MTBF), Mean Time to Repair (MTR), unscheduled downtime, maintenance costs, and the percentage of planned maintenance are met as per requirement.
Provide expert support for troubleshooting operational issues in packaging and container handling.
Ensure that periodic calibration activity of instruments are done as per SOP.
Responsible for the delivery of high-quality work output from all engaged vendors and consultants pertaining to process systems, meeting project specifications and timelines.
Proactively identify and implement areas for improvement during equipment selection and installation activities to optimize system performance, efficiency, and overall process reliability.
Equipment Selection & Configuration
Should be well versed with design and process engineering of packaging lines such as but not limited to Inspection Machine, Pen Device assembly Machine, Auto-injector assembly Machine, Auto cartonator, Labelling Machine, Blister Packing, Checkweigher, Cold room, BOPP Taping machine, Shrink wrapping machine, Track and Trace system etc.
Review User Requirement Specifications (URS) and participate in vendor evaluations and design reviews.
Provide SME input for line layout, component compatibility (e.g., stoppers, plungers, caps), and integration of upstream/downstream equipment.
Responsible for the preparation, review, and finalization of detailed process engineering designs and specifications for packaging equipment with a focus on process flow and system optimization.
Responsible for the preparation, review, and finalization of Bills of Quantity (BOQ) and Tender documents for Process Equipment’s/Systems, ensuring accurate process equipment and material specifications.
Responsible for the preparation, review, evaluation, and technical assessment of vendors for Process Equipment’s/systems, with a strong emphasis on process suitability, efficiency, and reliability. This includes the preparation and finalization of comprehensive technical comparison sheets to support informed process equipment and system selection.
Responsible for the preparation, review, and timely finalization of PFDs, P&IDs, and all associated process-related execution drawings.
Ensure proper integration of packaging machines with upstream/downstream machines such as RABS, filling machines, capping machines, Inspection machines etc. and supporting automation (SCADA, BMS, EMS).
Review P&IDs, layout drawings, and functional design specifications (FDS) for compliance with aseptic design principles.
Compliance, Validation & Documentation
Responsible for the preparation, review, and finalization of critical process technical documents, including process concept notes, process flow diagrams (PFDs), piping and instrumentation diagrams (P&IDs), and User Requirement Specifications (URS) for Process Equipment’s/systems, in close coordination with external consultants and cross-functional departments.
Responsible for the qualification and validation of packaging line is in line with regulatory requirements, focusing on process performance and quality attributes.
Drive and support investigations (e.g., deviations, CAPA, root cause analysis) related to packaging operations.
Cross-Functional Collaboration & Training
Serve as the technical liaison between quality, validation, manufacturing, and external vendors.
Train operations and engineering staff on equipment functionality, SOPs, and Good engineering practices.

Skills

Knowledge of packaging processes - vial, PFS, bag, and cartridge lines - Expert
knowledge of aseptic filling/packaging equipment, component compatibility, and regulatory requirements - Expert
container closure systems, vacuum/pressure-based CCIT, and serialization/in-line vision inspection systems - Expert.
Problem-solving, documentation, and cross-functional communication skills - Expert

Qualifications

Bachelor’s or Master’s degree in Mechanical or Process Engineering.
12–15 years of experience in injectable packaging processes, with hands-on expertise across vial, PFS, bag, and cartridge lines.
Deep knowledge of aseptic filling/packaging equipment, component compatibility, and regulatory requirements.
Familiarity with container closure systems, vacuum/pressure-based CCIT, and serialization/in-line vision inspection systems.
Excellent problem-solving, documentation, and cross-functional communication skills.