Overview The role is a critical role as Construction Manager for setting up the E2E Greenfield Foods project – civil MEP, utilities and infrastructure, Process line – and later takeover as Maintenance Manager covering asset reliability and engineering upkeep of the live plant. The person will ensure the timely, safe and quality construction and engineering delivery of the facility as per PepsiCo specifications, within budget, and thereafter sustain plant assets and utilities at peak reliability. Recruit, onboard and build capability of the maintenance and utilities team prior to commissioning of the Greenfield project.
This Greenfield will be first of its kind with huge complexities and scope – Manufacturing plant, ASRS with 6,500+ pallet positions, 20,000 MT long term modern cold storage within the facility, solar installation & Wind power PPA, IGBC Green building Gold certification and Zero Liquid Discharge (ZLD).
Responsibilities The role is to ensure E2E site Greenfield construction execution and subsequently taking over as Maintenance Manager for the live plant.
Construction / Project Execution Phase
- Provide expertise on civil, MEP and utilities, Process line engineering and construction.
- Greenfield construction management and execution as per PepsiCo requirements, in line with Capex budget & timelines.
- Ensure construction is executed as per overall India Food engineering strategy, PepsiCo GES / civil standards and statutory norms.
- Manage site mobilisation, contractor deployment, construction sequencing and site logistics.
- Lead Statutory license application & approval – pre construction & post construction
- Support execution of civil / PEB / MEP / utility packages together with construction Management team.
- Execute installation of buildings, utilities and infrastructure; drive construction quality (QA/QC) and snag closure.
- Drive site EHS – engage with Safety function on construction and equipment safety requirements and ensure zero-harm to standards.
- Conduct engineering commissioning of buildings and utilities prior to handover to manufacturing.
- Work with various stakeholders internally and externally like design consultants, PMC, contractors and statutory agencies and ensure quality of execution timely within the estimated cost.
- Take ownership of the construction and utility components of the productivity and sustainability agenda (IGBC Gold/Platinum, ZLD, renewable energy, water balance).
- Weekly, monthly reporting of construction progress, spend and safety.
- Recruit, onboard, build capability of the maintenance and utilities team prior to commissioning of the Greenfield project.
Maintenance / Operations Phase (post-takeover)
- Handling annual VMOH of $4-5MM, R&M of ~ $1MM, plant capex of $3-5 MM
- Designing, review and ensuring implementation of a maintenance system that optimizes efficiencies and costs and maximizes output.
- Review of daily activities in management Wall/team meeting and weekly and monthly operational goals and KPI’s review with supply chain finance along with the plant team.
- Participation in the monthly EHS (Environment, Health & Safety) review with the BU team and support the site EHS manager to drive the safety programs.
- Participation in the monthly Safety Committee Meeting to review and mitigation of the Near Miss, Hazards Identified.
- Discussion & alignment with the stakeholders (finance, sustainability & engineering) for all the site Capex Business Cases and submission of the same in Skelta portal.
- Liasoning with Engineering Design Consultants/Vendors/OEM for the finalization of technical details of the Capex projects and preparation of Technical Bid Summary.
- Ensuring cost effectiveness in planning, timely execution & forecast accuracy of significant CAPEX projects.
- Monthly review & capitalization as per CWIP.
- Half yearly review of the assets in the FAR and asset disposal (CADA) as per the guidelines.
- Up gradation of the technological competence of the plant and drive the productivity initiatives for the plant.
- Architecting along with the plant manager, an adaptive work culture in the plant and within the engineering team that promotes the company growth.
- Ensuring no production loss due to machine downtime beyond the budgeted downtime.
- Drive the implementation of PeMM (PepsiCo Excellence Maintenance Methodology) to deliver the improvement in listed workstreams as per guidelines.
- Ensuring the preparation of a timely and comprehensive AOP (Annual Operating Plan) for Repairs and Maintenance, Power & Fuel, FMOH (Fixed Monthly Over Heads) & VMOH (Variable Monthly Over Heads), Capex and ensuring its execution throughout the year.
Ensuring that the plant meets all the requirements of statutory bodies like MSEB, Weights and Measures Department, Boiler Inspector, Factory Inspectors, etc and submit the compliance in the online compliance reporting portal (PWC).
- Ensuring energy, water, and waste optimization through RECON implementation; identify and implement the best practises.
- Controlling the purchasing of spares and other engineering goods & drive Key Controls such as time-based physical verifications of the spares.
- Yearly review of Engineering Spares for categorizing as working spares, insurance spares & obsolete spares as per the guidelines.
- Drive the cataloguing exercise for the engineering spares and maximize the orders as per the catalogue.
- Leading the plant effectively along with other Team members.
- Increasing employee involvement in the functioning of the plant.
- Monitoring and controlling import substitution for reducing costs.
- Institutionalizing a hygiene and quality focussed culture.
- Lead MFS (Maintenance for Food Safety) pillar in AIB by maintaining hygienic conditions in the manufacturing, packaging, and utilities.
- Own and drive applicable EHS role & responsibilities, create awareness down the line for timely support and execution, GEHSMS standards and its compliances. Participate in the risk assessment and drive the MESS (Machine Equipment Safety Standard) compliance.
- Drive TPM
- Capability building & bench planning for Engineering function.
Qualifications - Overall 12+ years wherein majorly with construction / project execution and plant maintenance in Food/Bev or process manufacturing.
- 3+ years construction management experience; preferably with mid to large scale greenfield / brownfield investments.
- Good engineering knowledge of civil, structural (PEB), architectural, MEP, HVAC, utilities, water & WWTP (WTP/ETP/ZLD) technologies.
- Sound knowledge of maintenance systems – preventive / predictive maintenance, RCA, reliability engineering, CMMS/SAP-PM.
- Working knowledge of process/packaging equipment, line controls/automation, warehouse automation (ASRS) and cold-store (refrigeration) systems.
- Expert in understanding and applying global PepsiCo Civils / Utilities / Construction Engineering Specifications and safety standards.
- Equipped with hands-on skills to execute detailed construction reviews, inspections, PDI`s and engineering commissioning activities.
- Ability to read and modify ACAD technical drawings, GA / structural / MEP drawings, Gantt charts and developing URS / checklists.
- Exposure to green building (IGBC), renewable energy and sustainability execution.
- Exposure to working in a TPM culture.
- Technical Degree: Engineering (Civil, Mechanical & Electrical preferred).
Differentiated competencies
- Cost ownership and capex/opex discipline.
- Reliability and asset-care mindset; data-driven RCA and problem solving.
- Safety leadership – personal drive for zero-harm on a large construction site and in plant operations.
- Strong contractor / vendor management and on-site coordination capability.
- Self-motivated go-getter, able to work under a pressurised, deadline-driven environment.
- Excellent team management / leadership skills.
- Excellent / tactful communication, negotiation and influencing skills.
- High level of confidence & ability to carry himself/herself.
- Strong focus on delivery and results with high drive and energy levels.
- Exposure in dealing with statutory agencies tactfully and ethically.
- Ability to work in a matrix organization.