Production Engineering Track—The Technical Expert Path

Rohit, Production Engineer at a Pharmaceutical Manufacturing Facility

Rohit has been in this role for 2 years. Here’s what his typical week looks like:

Monday: Process Analysis

A batch of tablets is failing final inspection at 15% defect rate (should be <1%). Rohit investigates:

1. Collects data: Reviews production logs, quality reports, equipment sensor data
   
2. Maps the process: Documents every step: mixing → granulation → compression → inspection → packaging
   
3. Identifies variations: Notices compression force varies slightly between units (equipment calibration drifting?)
   
4. Tests hypothesis: Requests maintenance check equipment calibration
   
5. Finds root cause: Calibration was indeed off by 2%
   
6. Proposes solution: Implement automated calibration check every 2 hours
   
7. Analyzes impact: If implemented, defects drop to predicted 0.8%
   
8. Cost-benefit: Solution costs ₹2,00,000 implementation, prevents ₹50,00,000 in batch losses annually
   
   

Monday conclusion: Rohit presents findings to production manager with data-backed recommendation. Approval to proceed.

Tuesday: Process Redesign

New product launch next month. Current production design uses 8 steps. Rohit wants to streamline it:

1. Current state mapping: Documents existing process (wastes time, requires excessive handling)
   
2. Lean analysis: Which steps add value? Which are waste?
   
3. Redesigns process: Consolidates to 6 steps through better sequencing
   
4. Simulates new design: Uses manufacturing software to model new process
   
5. Predicts outcomes: New design should reduce cycle time 20%, reduce defects 15%
   
6. Tests new design: Runs pilot production with new process (100 units)
   
7. Measures results: Results match predictions: 22% cycle time reduction, 18% defect reduction
   
8. Documents: Creates work instructions for new process
   
   

Tuesday conclusion: Pilot successful. New process ready for full-scale launch. Rohit will train operators on the new procedure.

Wednesday: Equipment Evaluation

Company considering new automated packaging equipment (₹50,00,000 investment). Rohit’s role: technical evaluation.

1. Reviews equipment specifications
   
2. Compares to current process: How much improvement?
   
3. Calculates ROI: Cost vs. savings, payback period
   
4. Requests demo: Works with vendor to test equipment
   
5. Evaluates compatibility: How does new equipment integrate with existing systems?
   
6. Analyzes risks: What could go wrong? How do we mitigate?
   
7. Creates business case: ₹50 lakh investment saves ₹1 crore annually = 5-year payback, then pure profit
   
   

Wednesday conclusion: Rohit presents recommendation to management with detailed analysis. Equipment approved.

Thursday: Continuous Improvement Meeting

Rohit leads a cross-functional team: production supervisor, quality manager, maintenance technician, operators.

Agenda: Why is Equipment A consuming more power than last year despite same output?

Investigation:

• Maintenance tech: “Compressor bearings might be wearing”
  
• Quality manager: “Production parameters haven’t changed”
  
• Supervisor: “Operators say it sounds different”
  
• Operators: “Takes longer to reach pressure”
  
  

Rohit’s analysis:

• Reviews equipment logs: Startup time increased from 45 seconds to 68 seconds
  
• Requests bearing replacement
  
• Tracks energy consumption post-replacement: Returns to normal
  
• Cost: ₹50,000 preventive maintenance vs. ₹5,00,000 complete equipment replacement
  
  

Result: Problem prevented, massive cost savings, team learns to proactively monitor equipment.

Friday: Documentation & Planning

• Updates process documentation with Tuesday’s design changes
  
• Completes technical reports for Monday and Wednesday initiatives
  
• Plans next week: New operator training on redesigned process
  
• Reviews equipment maintenance schedule
  
• Prepares performance metrics for director meeting