Manager - PPC (Mandal)

Job Description:

Job Objective

To lead Production Planning & Control activities for the casting and machining operations, ensuring optimum utilization of manpower, machines and materials while achieving production targets, on-time delivery, inventory control and minimum WIP/FG levels.

The role will be responsible for developing production plans based on customer requirements, monitoring execution, coordinating with Production, Purchase, Stores, Quality, Maintenance and Dispatch teams, and driving improvement in planning efficiency.

2. Key Responsibilities

Production Planning

• Prepare monthly, weekly and daily production plans based on customer schedules and business requirements.
• Convert customer requirements into detailed production plans for Casting, Machining and downstream processes.
• Ensure production plans are aligned with available capacity, manpower, machine availability and material availability.
• Monitor plan vs. actual production and take corrective actions for deviations.
• Develop line-wise and process-wise capacity plans.

Material Planning & Control

• Coordinate with Purchase and Stores to ensure timely availability of raw materials, consumables, bought-out items and packaging materials.
• Monitor RM, WIP and finished goods inventory.
• Identify material shortages and initiate preventive actions.
• Maintain optimum inventory levels without affecting production or customer delivery.

PPC & Shop-Floor Coordination

• Closely coordinate with Production, Quality, Maintenance, Stores, Purchase and Dispatch teams.
• Monitor bottlenecks in Melting, Sand Plant, Moulding, Pouring, Fettling, Shot Blasting and Machining processes.
• Ensure smooth flow of castings from foundry to machining and dispatch.
• Control WIP and ensure adherence to FIFO wherever applicable.
• Prioritize production based on customer requirements and criticality.

Capacity Planning

• Prepare machine/process capacity analysis.
• Identify capacity constraints and bottleneck processes.
• Develop capacity utilization and loading plans.
• Coordinate with Production and Maintenance for planned machine shutdowns and maintenance schedules.
• Support capacity enhancement and new project planning.

Customer Delivery

• Ensure adherence to customer delivery schedules.
• Monitor customer schedules, dispatch requirements and pending orders.
• Prepare daily/weekly delivery commitment plans.
• Escalate potential delivery risks and implement recovery plans.

Inventory Control

• Monitor RM, WIP and FG inventory against defined norms.
• Reduce excess inventory, slow-moving stock and obsolete inventory.
• Improve inventory turns through effective planning.
• Ensure proper reconciliation of physical and system inventory.

ERP / MIS

• Ensure accurate and timely updating of PPC transactions in SAP/ERP.
• Monitor MRP, production orders, stock status and material requirements.
• Prepare daily/weekly/monthly PPC MIS reports.
• Track KPIs such as:
  • Plan vs. Actual Production
  • Schedule Adherence
  • On-Time Delivery
  • Inventory Days
  • WIP Levels
  • Capacity Utilization
  • Machine Loading
  • Production Losses
  • Customer Schedule Adherence

3. Cross-Functional Responsibilities

Work closely with:

• Production / Foundry
• Machining
• Quality
• Maintenance
• Purchase
• Stores
• Logistics / Dispatch
• NPD / Project
• Sales / Customer Coordination
• Finance

4. Improvement Responsibilities

• Drive Lean Manufacturing, Kaizen and continuous improvement initiatives in PPC.
• Optimize production sequencing and batch planning.
• Reduce waiting time, WIP and unnecessary inventory.
• Improve machine and manpower utilization.
• Develop systems for early identification of production and delivery risks.
• Support implementation of JIT / Kanban / FIFO practices wherever applicable.

5. Candidate Profile

Qualification:

• B.E./B.Tech – Mechanical / Production / Industrial Engineering
• Diploma with relevant experience may also be considered.

Experience:

• 10–15 years of experience in PPC / Production Planning & Control.
• Preferably from automotive components, foundry, casting, machining or auto-ancillary manufacturing.
• Experience in handling high-volume production and OEM customer schedules will be preferred.

6. Technical Skills

• Strong knowledge of PPC, MRP and production planning
• Capacity planning and machine loading
• Inventory and WIP control
• BOM and routing understanding
• Production scheduling
• SAP/ERP knowledge
• Excel / MIS / Dashboard preparation
• Knowledge of Lean Manufacturing / Kaizen
• Understanding of casting and machining processes
• Strong analytical and problem-solving skills

7. Key Competencies

• Strong planning and execution skills
• Leadership and team management
• Cross-functional coordination
• Decision-making ability
• Good communication skills
• Data analysis and MIS capability
• Problem-solving approach
• Ability to work under production and delivery pressure

8. Key Performance Indicators (KPIs)

• Production Plan Achievement
• Schedule Adherence
• Customer On-Time Delivery
• Inventory Reduction
• WIP Reduction
• Capacity Utilization
• Production Order Adherence
• Material Availability
• Planning Accuracy
• Reduction in Production Delays / Line Stoppages

9. Preferred Industry Background

Candidates from companies involved in:

Automotive Casting | Ferrous Foundry | Brake Disc / Drum | Auto Components | Machining | OEM / Tier-1 Auto Ancillary | High-Volume Manufacturing

will be preferred.

Location: Mandal / Vithalapur, Ahmedabad, Gujarat
Experience: 10–15 Years
Designation: Manager – PPC