Associate Director - External Manufacturing

Navin Fluorine International Ltd. · India

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&ID)
• 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 cost-saving proposals and value-improvement initiatives.
• Evaluate tolling cost structures and support commercial negotiations.

9. SOP, Batch Card & Manufacturing Documentation

• Prepare and Support to EM Partner:
• Standard Operating Procedures (SOPs)
• Batch Cards
• Work Instructions
• Process Manuals
• Cleaning Procedures
• Manufacturing Standards
• Ensure implementation and compliance at EM sites.
• Develop monitoring mechanisms for SOP compliance.
• Ensure proper documentation of production activities.
• Drive standardization across multiple manufacturing locations.

10. Inventory, Logistics & Reconciliation Management

• Closely track movement of:
• Raw Materials (RM)
• Packing Materials
• Semi-Finished Goods (SFG)
• Finished Goods (FG)
• Coordinate logistics between company sites and EM locations.
• Monitor inventory levels and prevent material shortages.
• Conduct periodic reconciliation of:
• Raw Materials
• Solvents
• Intermediates
• Finished Products
• Analyze inventory variances and take corrective actions.
• Coordinate with Supply Chain and Stores teams for inventory optimization.

11. EHS & Regulatory Compliance

• Conduct EHS assessments of EM manufacturing facilities.
• Ensure implementation of recommendations arising from:
• Safety Audits
• Process Safety Reviews
• Job Safety Analysis
• EHS Inspections
• Verify compliance with:
• Environmental Regulations
• Monitor closure of EHS observations and recommendations.
• Promote a strong safety culture at EM sites.

12. Stakeholder Management & Cross-Functional Coordination

Internal Coordination

Coordinate extensively with:

• Research & Development (R&D)
• Pilot Plant
• Technology & Development (T&D)
• Production
• Quality Assurance
• Quality Control
• Supply Chain Management
• Procurement
• Logistics
• EHS
• Commercial & Finance Teams

External Coordination

Coordinate with:

• EM Partner
• SCM
• Company Logistic dept.

13. Reporting & MIS

• Prepare and present:
• Weekly Progress Reports
• Campaign Reports
• Yield Analysis Reports
• Variance Reports
• Cost Optimization Reports
• Commercialization Status Reports
• Review weekly production progress against plans.
• Report operational risks and delays to management.
• Develop dashboards and performance metrics for EM operations.

Technical Competencies

• External Manufacturing Management
• Technology Transfer & Commercialization
• Process Scale-up
• BFD, PFD & P&ID Preparation
• Material & Energy Balance Calculations
• Yield Optimization & Cost Management
• Campaign Planning & Execution
• Continuous Chemical Process Operations
• Process Troubleshooting
• Root Cause Analysis (RCA)
• EHS & Process Safety Management
• Inventory & Reconciliation Management

Leadership Competencies

• Project Management
• Vendor Management
• Team Leadership
• Planning & Organizing
• Decision Making

Behavioral Competencies

• Strong Analytical Ability
• Result Orientation
• Problem Solving Mindset
• Proactive Approach
• Ownership & Accountability
• Collaboration & Teamwork
• Effective Communication Skills

14.Qualifications & Experience

Qualification

• BE / B. Tech – Chemical

Experience

• 12-18 years of experience in Chemical, Specialty Chemical, Agrochemical, Pharmaceutical, or MAH (Major Accident Hazard) Industries.
• Minimum 2-3 years of experience in External Manufacturing (EM) / Toll Manufacturing Operations preferred.
• Hands-on exposure to process scale-up, technology transfer, continuous improvement, and commercialization of chemical processes.

Experience handling critical high-pressure and high-temperature reactions.