Mechanical Engineer PPC - " Production , Planning , Control "

Job Title: Mechanical Engineer Production Planning and Control (PPC)

Department: Production / Manufacturing Operations

Reporting To: Factory Head / General Manager Operations

Job Purpose:

To ensure strategic and tactical planning scheduling monitoring and controlling of production activities related to precision fabrication of infrastructure formwork systems scaffolding systems decking systems renewable energy steel structures and custom fabrication projects maintaining highest quality productivity and delivery standards.

Job Description (JD):

1. Production Planning and Scheduling:

• Prepare Master Production Plans (MPP) based on confirmed orders forecasted demands and production capacities for:
• Precast Infra Formwork Moulds (U Girders FSLM U Ducts)
• Building Aluminium and Steel Formwork Systems
• Cuplock Ringlock Allshore Shoring Systems
• Solar and Wind Energy Structures
• Custom Steel Fabrication Projects
• Create detailed Weekly & Daily Production Schedules using ERP/MRP systems aligning machine loading manpower allocation and priority sequencing.
• Develop Work Order Travelers specifying raw materials processes (cutting bending welding assembly galvanizing painting) quality checkpoints and delivery dates.

2. Material Planning & Resource Management:

• Initiate Material Requirement Planning (MRP) including sheets pipes rods aluminium sections forgings castings and fasteners.
• Coordinate with Procurement for critical raw material lead times (especially imported aluminium profiles high-tensile steel).
• Plan consumables tools welding accessories and fixtures for uninterrupted production flow.

3. Production Execution Monitoring:

• Monitor work progress through Daily Production Reports (DPRs) against planned schedules.
• Identify and escalate any bottlenecks related to manpower machinery quality material or design.
• Optimize machine utilization in:
• CNC Cutting (Laser Plasma)
• Bending (CNC Press Brake)
• Welding (MIG TIG SAW)
• Galvanizing and Surface Treatment
• Drive priority-based execution for major infrastructure and renewable energy projects.

4. Quality Assurance Coordination:

• Collaborate with QA/QC to integrate In-Process Inspection Points (IPQC).
• Validate adherence to Dimensional Tolerances Welding Standards (ASME/ISO/EN) and Surface Finishing Standards (Galvanized Coating Thickness Paint DFT).
• Support NCR (Non-Conformance Report) management and implement corrective/preventive actions (CAPA).

5. Continuous Improvement & Efficiency Enhancement:

• Lead initiatives on:
• Lean Manufacturing (5S Kaizen Value Stream Mapping)
• OEE (Overall Equipment Effectiveness) Improvements
• Setup Time Reduction (SMED Techniques)
• Process Automation Opportunities
• Implement cycle time reduction strategies for high-volume fabrication like scaffolding parts and formwork accessories.

6. Documentation & Reporting:

• Maintain updated:
• Production Dashboards
• WIP Reports
• Inventory Ageing Reports
• Capacity Utilization Reports
• Productivity vs Planned Target Analysis
• Present Weekly and Monthly production reviews to Management.

7. Cross-functional Coordination:

• Act as an interface between Production Design Procurement QA/QC Dispatch and Sales teams.
• Attend Daily Review Meetings (DRMs) and Project Coordination Meetings (PCMs).

Key Responsibility Areas (KRA):

KRA

Details

Production Planning

Formulate monthly weekly and daily production schedules aligned with sales orders and projects.

Capacity Planning

Plan load balancing across cutting welding machining finishing and dispatch units.

Material Coordination

Ensure material availability at least 2 weeks ahead of scheduled production start.

Production Execution

Ensure >95% adherence to production schedules with minimum rescheduling.

Quality Compliance

Achieve zero major non-conformities in fabrication fitting and assembly stages.

Inventory Management

Maintain WIP inventory within 10% of monthly production value.

Process Improvement

Implement minimum 2 major lean initiatives or productivity improvement projects per year.

Manpower Management

Ensure effective utilization of shop floor manpower (fitter welder helper supervisor levels).

On-Time Dispatch

Ensure 95% dispatches within committed delivery timeline.

Key Performance Indicators (KPI):

KPI

Target / Benchmark

Production Plan Achievement

95% adherence to monthly production schedule

Machine Utilization

85% across cutting welding surface finishing

Manpower Productivity

Fabrication: 3 MT/Man/Month; Assembly: 150 Components/Man/Month

Delivery Compliance

95% of orders dispatched on time

Internal Rejection Rate

2% of total production output

External Rejection Rate (Client Rejection)

1% of dispatched products

Material Planning Accuracy

98% right-first-time material availability

Wastage Rate

3% of material input

Cost of Poor Quality (COPQ)

1.5% of monthly production value

Cycle Time Reduction

Minimum 10% YoY reduction in identified product categories

Kaizen Implementation

Minimum 1 Kaizen / Process Improvement idea implemented per quarter

Technical Expertise Required:

• Advanced knowledge of steel fabrication aluminium fabrication galvanization and surface finishing.
• Understanding of international codes and standards:
• AWS D1.1 (Welding)
• ISO 3834 (Quality in Welding)
• ASTM / EN standards for structural steel and formwork systems.
• Familiarity with:
• ERP Systems (SAP Oracle Tally Prime ERP)
• Planning Tools (MS Project Primavera P6 preferred but optional)
• Quality Tools (Pareto Analysis Fishbone Diagram 8D Reports)

Qualification and Experience:

• B.E. / B. Tech (Mechanical Engineering) Mandatory
• 4 8 years experience in production planning preferably in fabrication-heavy industries (Formwork Scaffolding Solar/Wind Structures Infrastructure Equipment).