Ppc Manager

1. Scope & Objective of the role

Production planning is a strategic process that involves determining what products to produce, when, and how, based on demand forecasts, available resources, and capacity. It aims to balance supply with demand while ensuring the smooth operation of production systems.

Objectives of Production Planning

• Meet customer demand

  within lead time and quality requirements.

• Minimize production costs

  by optimizing resources (e.g., materials, labor, machines).

• Maximize throughput

  and efficiency.

• Ensure inventory management

  is aligned with production needs.

• Reduce downtime

  by anticipating bottlenecks or potential problems.

2. Roles & Responsibilities

• Responsible for PPC for Rajajinagar Plant.
• Ensure smooth Flow of materials from Rajajinagar to SEZ
• Ensure capacity for SEZ is fulfilled by smooth flow of materials.
• Responsible for delay in production in SEZ plant.
• Responsible for KPIs of the team members
• Responsible for OTD
• Identify the bottleneck and act accordingly.
• Pro-active in his decision making capability
• Responsible for complete planning of materials from Raw material to deliver to SEZ

2. Job Profile

1 Demand Forecasting

• Description

  : Forecasting demand helps the production team determine the volume of products to produce in the coming period.

• Activities

  :
• Analyze historical sales data, market trends, and customer orders.
• Use forecasting models (e.g., moving averages, regression analysis).
• Coordinate with sales and marketing to understand promotional activities and market conditions.

• Outputs

  : Forecasted demand for the period (e.g., weekly, monthly & quarterly).

2 Capacity Planning

• Description

  : Assessing the production facility’s ability to meet forecasted demand using available resources (e.g., machines, labor, and workstations).

• Activities

  :
• Identify bottlenecks in production capacity.
• Evaluate resource availability (human, material, and machine).
• Calculate required production rates and time.

• Outputs

  : Production capacity plan, identifying constraints or resource shortages.

3 Materials Requirement Planning (MRP)

• Description

  : Ensuring that the required raw materials, components, and parts are available for production.

• Activities

  :
• Break down the bill of materials (BOM) for each product.
• Create material procurement plans based on demand forecast and production schedules.
• Monitor inventory levels and reorder materials as necessary.

• Outputs

  : Materials plan, purchase orders, inventory reports.

4 Inventory Management

• Description

  : Maintaining inventory levels that align with production schedules and customer demand without overstocking or stockouts.

• Activities

  :
• Track finished goods, WIP, and raw materials inventory.
• Adjust inventory levels based on production forecasts and demand changes.
• Use inventory management tools (e.g., ERP systems) for real-time tracking.

• Outputs

  : Inventory levels, reorder reports, stock movement reports.

5 Dispatch and Delivery

• Description

  : Coordinating the delivery of finished goods to customers in alignment with sales and customer orders.

• Activities

  :
• Plan for the timely dispatch of finished goods.
• Ensure transportation resources (e.g., courier, transport, Porter) are available.
• Communicate with sales and logistics teams to ensure customer satisfaction.

• Outputs

  : Dispatch plans, delivery schedules, shipment tracking reports.

3. Tools & Systems to support

• Enterprise Resource Planning (ERP) Systems

  : Integrated platforms that help manage all production resources using SAP, Microsoft Dynamics.

• Material Requirements Planning (MRP)

  : Develop systems with the help of Sales.

• Gantt Charts

  : Visual project management for scheduling and tracking production progress using Microsoft XL.

• Kanban Systems

  : Lean inventory management system for controlling the flow of materials through production.

• Value Stream Mapping (VSM):

  This data to be used to calculate hidden costs of manpower.

• 5S

  to eliminate waste and improve efficiency.

4. Continuous Improvement

• Root Cause Analysis

  : Identifying the underlying causes of production delays, inefficiencies, or quality issues.

.

5. Key Deliverables (KPIs)

1. On-time delivery rate

   – Percentage of orders delivered on time.

2. Production lead time

   – Time taken to produce items from order receipt to completion.

3. Production efficiency

   grid

   – Output per unit of input (e.g., labor, machine hours).

4. Inventory turnover

   – Rate at which inventory is used or sold and replaced.

5. Capacity utilization

   – The percentage of available production capacity that is being used.

6. Defect rate

   – Percentage of products that fail to meet quality standards.

7. Stockouts

   – Frequency of running out of stock for key materials or finished goods.

8. Customer satisfaction

   – Percentage of customers satisfied with product quality, delivery time, and order fulfillment.