Production Planning & Control Engineer

Job Purpose

To plan, schedule, and monitor production activities across the steel foundry and downstream processes to ensure on-time delivery, optimum capacity utilisation, controlled inventory, and smooth coordination between melting, moulding, fettling, heat treatment, machining, and dispatch.

Key Roles & Responsibilities

1. Production Planning & Scheduling

• Prepare monthly, weekly, and daily production plans based on:
• Customer delivery schedules
• Sales orders / forecasts
• Available melting, moulding, and finishing capacities
• Convert customer schedules into:
• Heat plans
• Moulding schedules
• Fettling and heat-treatment plans
• Prioritise orders based on:
• Customer criticality
• Export vs domestic commitments
• Penalty / SLA requirements
• Balance load across shifts and equipment to avoid bottlenecks.

2. Capacity Planning & Load Analysis

• Evaluate and monitor capacity of:
• Induction furnaces / ladles
• Moulding lines
• Fettling bays
• Heat-treatment furnaces
• Machining (if in-house)
• Identify overloads or under-utilisation and propose:
• Shift changes
• Overtime
• Sub-contracting (if applicable)
• Support management in capacity expansion and CAPEX planning using data.

3. Material & WIP Control

• Ensure availability of:
• Moulding sand, resins, sleeves
• Alloys and charge mix
• Consumables critical to production flow
• Control WIP at each stage:
• Moulding → Knockout
• Fettling → Welding
• Heat treatment → Inspection
• Minimise excessive WIP and waiting time between processes.

4. Inter-Departmental Coordination

• Coordinate closely with:
• Melting & moulding teams for heat readiness
• Fettling and welding for throughput planning
• Quality for inspection and NDT sequencing
• Maintenance for planned downtime
• Dispatch & logistics for shipment readiness
• Act as the single point of coordination between Sales, Production, and Quality.

5. ERP, MIS & Reporting

• Create and maintain production plans in ERP / Excel / planning tools.
• Track and report:
• Plan vs actual production
• Delays and reasons
• WIP ageing
• On-time delivery (OTD)
• Generate daily, weekly, and monthly MIS reports for management.
• Ensure data accuracy for:
• Sales orders
• Production confirmations
• Inventory movements

6. Delivery & Customer Commitment Management

• Ensure adherence to committed delivery dates.
• Proactively flag risks related to:
• Capacity constraints
• Material shortages
• Quality hold-ups
• Support Sales in:
• Revised delivery commitments
• Recovery plans for delayed orders
• Coordinate expediting for urgent or premium orders.

7. Continuous Improvement & Process Optimisation

• Analyse production data to:
• Reduce lead time
• Improve throughput
• Lower inventory carrying cost
• Participate in:
• APQP and new part introduction planning
• Bottleneck elimination initiatives
• Lean / TPM / Kaizen activities
• Suggest improvements in planning logic and sequencing.

Key Deliverables (Measurable Outputs)

• Realistic and executable monthly and weekly production plans
• Consistent on-time delivery performance
• Balanced capacity utilisation across foundry operations
• Reduced WIP and improved material flow
• Accurate and timely production MIS reports
• Effective coordination with minimal firefighting
• Improved visibility of risks and constraints to management

Key Performance Indicators (KPIs)

• On-Time Delivery (OTD %)
• Plan vs Actual production adherence
• WIP ageing and inventory turnover
• Capacity utilisation %
• Schedule changes / plan stability
• Customer delivery escalations

Qualifications & ExperienceEducation

• BE / BTech / Diploma in Mechanical / Production / Metallurgy / Industrial Engineering

Experience

• 3–7 years in production planning or PPC in a steel foundry or heavy engineering environment
• Hands-on experience with multi-stage manufacturing preferred

Required Skills & Competencies

• Strong understanding of steel foundry processes and constraints
• Capacity planning and scheduling skills
• ERP / Excel proficiency (pivot tables, trackers, formulas)
• Analytical and problem-solving ability
• Clear communication and coordination skills
• Ability to work under delivery pressure

Authority & Responsibility

• Authority to plan and reschedule production within approved limits
• Responsibility for production flow and delivery adherence
• Accountability for delays due to planning or coordination gaps

Job Types: Full-time, Permanent

Pay: ₹25,000.00 - ₹30,000.00 per month

Benefits:

• Cell phone reimbursement
• Health insurance
• Provident Fund

Experience:

• Steel foundry total work: 1 year (Preferred)

Work Location: In person