Production Technician (BFS Manufacturing) at Adcock Ingram

MAIN TASKS / RESPONSIBILITIES:

Production Operations

• Operate and monitor Rommelag BFS machines during production runs.
• Ensure production targets are achieved while maintaining product quality standards.
• Perform machine start-ups, shutdowns, product changeovers, and mould changes.
• Set up and control BFS process parameters relating to polymer extrusion, parison control, mould temperature, cooling, cutting, sealing, and container formation.
• Conduct line opening and line clearance activities in accordance with approved procedures.

Monitor critical process parameters, including:

• Temperature
• Pressure
• Fill volume
• Bottle weight
• Cycle times

Polymer melt condition and extrusion stability

• Sealing integrity

PLC alarms, interlocks, sensor feedback, and automated control status

• Ensure correct machine setup and operational readiness before production commencement.
• Report production outputs, process deviations, and equipment issues accurately and timeously.

Equipment Maintenance & Troubleshooting

• Perform first-line maintenance on BFS equipment and associated systems.
• Use machine HMI and PLC feedback to identify alarms, abnormal operating conditions, process deviations, and equipment interlock issues.
• Conduct routine machine inspections and preventive maintenance activities.
• Troubleshoot mechanical, electrical, pneumatic, hydraulic, and process-related faults.
• Diagnose BFS-related process issues linked to polymer flow, extrusion instability, mould alignment, trimming, sealing defects, container formation, and plastic material performance.
• Identify and escalate equipment abnormalities for further technical intervention when required.
• Assist Engineering and Maintenance teams during major maintenance and breakdown investigations.
• Ensure equipment remains in optimal operational condition to minimize downtime.

Quality Assurance

• Perform in-process quality inspections according to SOPs, GMP requirements, and batch documentation.

Monitor and inspect products for:

• Leaks
• Bottle weight compliance
• Fill volume accuracy
• Seal integrity
• Flashing defects
• Cosmetic defects
• Particulate contamination
• Print quality and traceability

• Complete all production and quality documentation accurately and legibly.
• Participate in deviation investigations, root cause analyses, and corrective action implementation.
• Support root cause analysis investigations by gathering process information, reviewing machine trends or events, identifying contributing factors, and documenting investigation outcomes.
• Prepare clear, factual, and GMP-compliant deviation, investigation, and technical reports where required.
• Assist with batch reconciliation and release-related activities.

Cleaning & Housekeeping

• Clean and sanitize BFS machines and production equipment according to approved procedures.
• Maintain housekeeping standards within manufacturing and cleanroom areas.
• Ensure adherence to contamination-control procedures and sterile gowning requirements.
• Participate in scheduled cleaning and sanitization programs.

Safety, GMP & Compliance

• Adhere to all Occupational Health and Safety regulations and company safety procedures.
• Always wear and maintain required PPE.
• Comply with GMP, SOPs, work instructions, and regulatory requirements.
• Participate in audits, inspections, training programs, and compliance initiatives.
• Apply pharmaceutical, GMP, and QMS training in daily operations, documentation practices, deviation handling, and compliance activities.
• Identify and report safety hazards, near misses, and unsafe conditions.

Continuous Improvement

• Contribute to process improvement initiatives aimed at increasing machine efficiency and reducing waste.
• Participate in root cause investigations and problem-solving activities.
• Use structured problem-solving tools to support root cause analysis, CAPA development, and documented effectiveness follow-up.
• Support implementation of corrective and preventive actions (CAPA).
• Assist in achieving departmental productivity, efficiency, and quality objectives.

Requirements

Qualifications

• Grade 12 / Matric.
• National Diploma, N6, Trade Certificate, or equivalent qualification in Mechanical Engineering and/or Electrical Engineering.
• Technical qualification with exposure to automated manufacturing equipment.
• Pharmaceutical manufacturing, GMP, and Quality Management System (QMS) training would be advantageous.
• BFS Technology qualification from the Plastics Institute or equivalent training would be advantageous.
• Dual qualification in Mechanical and Electrical disciplines (advantageous)
• PLC, automation, or instrumentation training (advantageous).
• Training in deviation management, root cause analysis, CAPA, and technical report writing would be advantageous.

  Experience 

• Minimum 3-5 years' experience in a pharmaceutical, sterile manufacturing, FMCG, packaging, or production environment.
• Experience operating, maintaining, or troubleshooting Rommelag Blow-Fill-Seal (BFS) filling equipment is highly advantageous.
• Practical experience with BFS process optimisation, including parison formation, mould operation, sealing performance, container integrity, and process parameter control.
• Experience working with pharmaceutical-grade polymers and plastics manufacturing principles, including extrusion, moulding, cooling, trimming, defect identification, and material-related troubleshooting.
• Experience performing first-line maintenance, fault finding, and equipment troubleshooting.
• Experience conducting line clearance, line opening, and changeover activities.
• Experience working within a GMP-regulated environment.
• Exposure to pharmaceutical training, QMS processes, deviation management, and CAPA systems would be advantageous.
• Experience participating in root cause analysis investigations and compiling clear investigation reports would be advantageous.
• Experience operating automated production equipment and process control systems.
• Experience operating, interpreting, and responding to PLC-controlled machine interfaces, alarms, interlocks, sensors, and automated process controls.
• Strong electronic, mechanical, and PLC fault-finding experience on automated filling or manufacturing equipment.
• Experience in cleanroom manufacturing environments would be advantageous.

Languages

• Proficient in written and spoken English.
• Additional South African languages would be advantageous.

Other

• Ability to read, understand, and complete technical documentation, SOPs, batch records, and quality documentation in English.
• Ability to work rotating shifts, weekends, public holidays, and overtime as required.
• Ability to wear sterile gowning and PPE for extended periods.
• Strong mechanical, PLC and electrical troubleshooting capability.
• High level of attention to detail and commitment to quality.
• Ability to work independently and within a cross-functional team.
• Must demonstrate a strong commitment to safety, GMP compliance, and continuous improvement.
• Computer literacy, including Microsoft Office and manufacturing-related electronic systems.
• Operation of Equipment with PLC
• Reliable transport to accommodate shift work requirements.