Senior Engineer - PPC

Role & responsibilities

Production Planning & Scheduling

• Prepare daily, weekly, and monthly production plans based on customer demand and sales forecasts.
• Develop production schedules considering machine capacity, manpower availability, tooling requirements, and material availability.
• Monitor plan versus actual production and initiate corrective actions for deviations.
• Ensure adherence to delivery schedules and customer requirements.

Production Control

• Track order execution from planning to dispatch.
• Monitor WIP (Work-in-Progress) levels and ensure smooth production flow.
• Identify bottlenecks and work with cross-functional teams to resolve constraints.
• Review production performance and maintain optimal resource utilization.

Material Planning & Inventory Management

• Coordinate with procurement and stores for timely availability of raw materials, bought-out parts, and consumables.
• Monitor inventory levels and minimize excess stock and shortages.
• Ensure optimum inventory turns while maintaining uninterrupted production.
• Follow up with suppliers for critical materials impacting production plans.

Customer Order Management

• Review customer schedules and demand fluctuations.
• Monitor order fulfillment and on-time delivery performance.
• Coordinate with customers and internal teams for schedule changes and urgent requirements.
• Maintain delivery commitments and customer satisfaction.

Capacity Planning

• Analyze machine and manpower capacities against demand forecasts.
• Recommend capacity enhancements, overtime requirements, or outsourcing as needed.
• Support annual business planning and budgeting processes.

Data Analysis & Reporting

• Generate and analyze PPC reports and KPIs.
• Prepare production plans, inventory reports, delivery performance reports, and capacity utilization reports.
• Present MIS reports to management on a periodic basis.
• Drive data-based decision-making for production optimization.

Continuous Improvement

• Support Lean Manufacturing, TPM, Kaizen, and Cost Reduction initiatives.
• Identify opportunities for improving planning accuracy, inventory control, and production efficiency.
• Participate in process improvement projects and digitalization initiatives.

ERP/System Management

• Ensure accurate transactions and master data management in ERP/MRP systems.
• Utilize SAP or similar ERP systems for planning and monitoring activities.
• Maintain planning parameters and production-related data integrity.

Key Performance Indicators (KPIs)

• Production Plan Adherence (%)
• On-Time Delivery (OTD)
• Inventory Turnover Ratio
• Schedule Adherence
• Material Availability (%)
• Capacity Utilization (%)
• WIP Inventory Levels
• Forecast Accuracy
• Customer Delivery Performance
• Stock-Out Incidents