Head, Pilot Plant ( Mngr/Sr Mngr level)

1. Role Purpose

The Sr. Manager / Associate Director Continuous Pilot Plant is responsible for leading the operation, development, optimization continuous process technologies in pilot plant facilities. The role bridges between technology development and shopfloor execution. The position plays a critical role in accelerating commercialization of new products, improving process efficiency, and supporting innovation initiatives. To lead shopfloor operation in a safe and environment friendly manner

2. Key Responsibilities

Continuous Pilot Plant Operations

1. Lead end-to-end operation of continuous pilot plant facilities for process development and scale-up activities.
2. Plan and execute pilot plant campaigns production, process optimization, and debottlenecking studies. Generate operational data base for further analysis for design utilisation
3. Ensure safe, reliable, and efficient operation of continuous reactors, separation systems, and downstream processing equipment.
4. Monitor pilot plant performance and ensure adherence to operating procedures and safety standards.
5. Maximize pilot plant utilization while maintaining quality and operational excellence.

Process Development & Scale-Up

1. Evaluate processes under continuous manufacturing conditions.
2. Generate critical engineering and scale-up data required for commercial plant design.
3. Optimize reaction parameters, throughput, productivity, yield, selectivity, and energy consumption in coordination with technology department

Process Safety & Risk Management

1. Lead process risk assessments, HAZOP studies, and safety reviews for pilot plant operations.
2. Ensure compliance with Process Safety Management (PSM), MOC, and plant safety standards.
3. Develop emergency response procedures and safe operating practices.
4. Investigate incidents, deviations, and near-miss events and implement corrective actions.
5. Promote a strong process safety culture within the team.

Quality Assurance

1. Ensure all processes in pilot plant executed as per standard quality procedures
2. Ensure requirements related to finished product / intermediates and packaging are fulfilled.
3. Ensure proper handling of customer supplied resources.

Cross-Functional Coordination

1. Coordinate closely with R&D, Production, Engineering, QA, QC, Projects, EHS, and Supply Chain teams.
2. Support customer visits, technology reviews and technical due diligence activities.
3. Work with equipment vendors and consultants during pilot plant upgrade projects.
4. Provide technical leadership to multidisciplinary project teams.
5. Ensure alignment of pilot plant activities with business objectives and commercialization timelines.

Documentation & Compliance

1. Maintain pilot plant operation log records, process reports, technical documentation and study reports.
2. Prepare campaign report covering productivity and quality aspects related to product / intermediate.
3. Ensure compliance with ISO, GMP (where applicable), Responsible Care and company quality systems.
4. Track technical performance metrics and project milestones.
5. Present technical findings and recommendations to senior management.

People Management

1. Lead and mentor Pilot Plant Engineers, Scientists, Operators and Technicians.
2. Develop team capabilities in continuous processing, scale-up, and process safety.
3. Conduct performance reviews and training programs for team members.
4. Foster a culture of innovation, collaboration, and operational excellence.