Senior PPC Engineer (Machine Shop, Steel Roll Industry)

Job Title: Senior PPC Engineer (Machine Shop, Steel Roll Industry)

Department:

Job Purpose

To lead production planning, machining planning, cycle time calculation, and process coordination across casting, machining, finishing, and dispatchensuring on-time delivery, optimized machine utilization, and high-quality output.

Key Responsibilities

1. Production Planning & Scheduling

• Prepare daily/weekly/monthly production plans based on customer orders and plant capacity.
• Plan machine loading with estimated machining hours for roughing, semi-finish, and finish operations.
• Create shift-wise routing considering machine availability, tool life, operator skill, and inspection stages.

2. Engineering Drawing & Technical Understanding (New Section)

• Must be able to

  read and interpret engineering drawings

  accurately.
• Should understand:
• Dimensions & tolerances (GD&T)
• Surface finish symbols
• Machining symbols
• Fits & clearances
• Ability to convert drawings into

  machining process plans

  , including steps, tools, cycles, and inspection points.
• Should be able to generate the

  machining profile and sequence

  required to produce a roll or component.

3. Machining Operation Planning & Control (Strong Technical Section)

Knowledge of Machines

Must have strong practical knowledge of operating parameters of:

• Lathe machines (CNC & conventional)

• VTL/Turning centers

• Milling machines

• Drilling & Tapping machines

• Grinding machines

• Roll turning & finishing machines

Cutting Tools & Tooling Knowledge

• Knowledge of:
• Carbide inserts, grades, nose radius, holders
• Boring bars, threading tools, boring heads
• Drills, taps, end mills, side & face cutters
• Grinding wheels, dressing tools
• Selection of appropriate tooling based on material & machining stage.
• Understanding of

  tool life

  , tool wear, and tool-change frequency.

Cutting Parameters & Machining Calculations

Should have strong knowledge of:

• Cutting speed (Vc)
• Spindle speed (RPM)
• Feed rate (f)
• Depth of cut (DOC)
• Material removal rate (MRR)
• Cycle time calculation for all machining operations

calculate machining hours

Machining Sequence & Profile Generation

• Should be able to determine:
• Roughing parameters
• Semi-finishing parameters
• Finishing & grinding parameters
• Define step-by-step machining process for each component.

4. Quality, Tolerance & Testing Knowledge

• Knowledge of

  tolerance measurement tools

  : micrometers, vernier, height gauge, bore gauge.
• Understanding of:
• Circularity, straightness, runout
• Surface finish (Ra values)
• Hardness checking
• Knowledge of

  pressure testing

  requirements for relevant components.
• Coordinate with QA for profile inspection, dimensional checks, and quality release.

5. Coordination & Shop Floor Control

• Daily coordination with melting, moulding, heat treatment, machining & dispatch teams.
• Identify bottlenecks (tool failures, machine downtime, manpower gaps).
• Conduct daily Plan vs Actual” review and push corrections.

6. Data, Reports & Compliance

• Ensure accurate SAP/ERP entries for machining progress, WIP, and dispatch.
• Maintain tool consumption data, cycle time sheets, and machine capability charts.
• Follow ISO 9001:2015 procedures and internal SOPs.

Skills & Competencies

• Strong drawing reading & GD&T interpretation
• Excellent machining process knowledge
• Ability to calculate speeds, feeds, and cutting rates
• Understanding of roll machining / heavy machining environment
• Strong communication, planning & coordination skills
• Excellent Excel + SAP/ERP skills

Qualification & Experience

• B.Tech / BE in Mechanical / Production / Metallurgy

• Must be from NIT or similar Tier-1 engineering institute

• 8–10 years of experience

  in:
• Steel industry
• Casting industry
• Forging industry