SANKARI MADDU
Visakhapatnam,India
Summary
- SKILLS SUMMARY
- 13 years of work experience as a Process Engineer with Scale up and technology transfer of APIs including 8+ years of Team Leading experience.
- Currently handling a team size of 12 direct reporting engineers and collaborating daily with 15-20 members of cross functional team.
Overview
14
14
years of professional experience
Work history
MSAT Functional Leader (Manager
Biocon Limited
Visakhapatnam
2022.01 - Current
- Established MSAT function at Vizag sites
- Recruited team with full capabilities to support immunosuppressants, non-potent and potent molecules
- Increased capacity of a commercial product from 16MT to 24MT which contributed 26 Cr Revenue addition and overhead reduction from $130 TO $90 per Kg
- Line Balancing, Bottleneck Analysis
- Capacity Analysis, & Value stream mapping
- Identified and projected total 11Cr potential solvent recovery streams to management from Vizag manufacturing plants
- Introduced new technologies like Inline Dilution system (ILBC) for 35% increase in the capacity of an immunosuppressant product
- Successfully mapped 4 new Onco products for validations and proposals given for Onco pilot plant with multipurpose including maximum capabilities
- Capacity Mapping done for non-onco product for 2MT capacity with 3Cr Capex
- Earlier the same product had been mapped with 25Cr capex
- Involved in Scale up and technology transfer of commercial CIP products.
Team Leader (Associate Manager
Biocon Limited
Bangalore
2018.05 - 2021.01
- Supported with basic Process Engineering work on submitting proposals to Contract Manufacturing projects
- Worked on total 7 projects and out of that 3 projects are successful, and one project is under discussion with the client
- Process intensification and suggesting alternative technologies like Agitated Thin Film Drying and Spray Drying are some of the key factors which made these projects effective
- Successfully scaled up and completed process validation of two API molecules matching with customer Formulation requirement with no delays
- Responsibility of Networking with Industry Experts for new technologies.
Team Leader (Deputy Manager
Biocon Limited
Bangalore
2016.05 - 2018.04
- Interacting with cross functional product delivery team (at least 10-15 members on daily basis) for smooth execution of the projects
- Successfully scaled up and validated a complex API project
- Developed skills like preparing and analysing cost sheets and verifying potential areas of cost reduction possibilists
- Skilled in conducting a thorough ‘Literature Search' for troubleshooting complex issues
- As part of CIP drive, introduced Helium Degasification of methanol Solvent for a Preparative High-Pressure Liquid Chromatography step and increased the step yield by 33% and overall cost reduction by 24%
- Identified & diagnosed a product diffusion phenomenon in Nano filter membranes and modified to run the system based on Van't Hoff's equation
- This resulted a 6% cost reduction of the product.
Process Engineer (Assistant Manager
Biocon Limited
Bangalore
2014.05 - 2016.04
- Successfully scaled up a project in a Lead Role and started taking the responsibility of leading the projects with two direct reporting engineers
- Played a key role in assisting conceptual design and Project work for creating additional capacity of this product with 14 Cr investment in a brown field project
- Debottlenecked existing huge volume reactor concentrations by using a Wiped Film Evaporator and made three 15KL reactors and one 7.5KL reactor set up available for this project
- Assisted in sizing of Reactors, Liquid-Solid separators and preparative HPLC columns and powder processing equipment.
Team Member (Senior Executive
Biocon Limited
Bangalore
2012.01 - 2014.04
- Skilled in doing basic chemical engineering calculations like mass & energy balance sheets
- Preparation of Process Flow Diagrams, P&IDs & HAZOP studies
- Assisted in making schedules using Gantt charts and highlighting key milestones for smooth operational execution
- Assisted in working on a variable costing methodology for utility consumption.
Team Member (Jr. Manager
Dr Reddy Laboratories
2010.07 - 2012.01
- Assisted in Technology Absorption and continuous batch monitoring at shop floor of a Peptide molecule
- Assisted in facility erection including peptide synthesizer, nanofiltration & Lyophilizer systems.
Education
undefined
2011
Maters Degree - undefined
Indian Institute of Technology
2010
Bachelor's Degree - undefined
Andhra University
2008
Accomplishments
- Assisted “Leadership Team” in selection of products, supply chain planning and optimization of Asset utilization
- Skilled in exhaustive detailing of downtime analysis of process and identifying technology opportunities for the best fitment of products
- In recent work, reduced CAPEX from the initial projection of ~300Cr to 196Cr of a capacity expansion project and helped to make a viable business case
- Capacity mapping done for 5 non-immunosuppressant products in 4 product value streams and 5 production blocks
- Data analysis of multiple products, debottlenecking & process intensification ideas are used as levers in accomplishing the best design option with reasonable investment
- Expertise in Data collection and Data Evaluation using “Pareto Analysis”
- Skilled in reviewing process health by checking DCS trends and cross verifying the variance of critical variables
- Quick in data collection, analysis & Troubleshooting
- Worked on Solvent recovery drive in Biocon and collected huge data bank of Product CCs of 20 products and skilfully conducted nodal analysis.
Additional Information
- HONORS AND AWARDS , Coromandel Fertilizers Ltd Gold Medal for achieving as a Department topper Rao Sahab C.D. Dasa Rao prize for the best Academic performance in Graduation Recognized and Awarded with “Certificate of Excellence” for driving one of my recent Projects with flawless execution and meeting customer requirement. Recognized and Awarded with “Certificate of Excellence” for reducing the cost significantly in one of my projects.
Timeline
MSAT Functional Leader (Manager
Biocon Limited
2022.01 - Current
Team Leader (Associate Manager
Biocon Limited
2018.05 - 2021.01
Team Leader (Deputy Manager
Biocon Limited
2016.05 - 2018.04
Process Engineer (Assistant Manager
Biocon Limited
2014.05 - 2016.04
Team Member (Senior Executive
Biocon Limited
2012.01 - 2014.04
Team Member (Jr. Manager
Dr Reddy Laboratories
2010.07 - 2012.01
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Maters Degree - undefined
Indian Institute of Technology
Bachelor's Degree - undefined
Andhra University