Manufacturing Operations & PPC (Production Planning & Control)

GOPALAN METALS

Designation

Manager / Senior Manager Manufacturing Operations & PPC (Production Planning & Control)

Experience

Minimum 10 years of relevant manufacturing experience

Work Location

Hoskote, Bengaluru, Karnataka (confirm based on plant location)

JOB DESCRIPTION

Position Overview

Gopalan Metals is seeking an experienced manufacturing professional to strengthen factory operations, production planning, quality systems, maintenance, inventory control and continuous improvement. The successful candidate will establish disciplined, measurable processes across the manufacturing function, improve productivity and cost efficiency, and support the implementation and maintenance of recognised quality, environmental and occupational health and safety standards.

Experience Required

Minimum 10-16 years of relevant experience in manufacturing operations, preferably in copper, non-ferrous metals, metal processing, engineering, automotive components or a related industrial environment. Candidates should have substantial shop-floor exposure and experience coordinating production, quality, maintenance, planning and cross-functional teams.

Key Responsibilities

1. Integrated Management Systems (IMS) & Compliance

• Implement, maintain and improve an Integrated Management System aligned with applicable standards and business requirements.
• Lead or coordinate systems and audit readiness for IATF 16949, ISO 9001, ISO 14001 and ISO 45001, where relevant to the organisation and customer requirements.
• Manage internal audits, corrective and preventive actions, non-conformities, document control and management reviews.
• Ensure compliance with applicable statutory, environmental, safety and customer-specific requirements.

2. Production Planning & Control (PPC)

• Prepare production plans and schedules based on orders, capacity, manpower, material availability and delivery commitments.
• Monitor production output, utilisation, bottlenecks, yield, downtime and on-time delivery.
• Coordinate with sales, procurement, stores, quality and dispatch teams to ensure smooth production flow.
• Establish daily, weekly and monthly operational dashboards and review routines.

3. Quality Assurance & Audits

• Strengthen incoming, in-process and final quality controls, inspection plans and traceability.
• Drive root-cause analysis and corrective actions using tools such as 5 Why, Fishbone, 8D and CAPA.
• Monitor customer complaints, rejection rates, rework, scrap and cost of poor quality.
• Coordinate customer, supplier, certification and internal audits as applicable.

4. New Product Development (NPD)

• Coordinate feasibility reviews, process trials, validation, documentation and production readiness for new products.
• Work with technical, quality, production, procurement and customer-facing teams to meet specifications and launch timelines.
• Maintain relevant process documentation, control plans, risk assessments and lessons learned.

5. Inventory Management WIP & Finished Goods

• Improve visibility and control of raw materials, work-in-progress (WIP), consumables and finished goods.
• Establish stock accuracy, material traceability, cycle counting, ageing reviews and inventory reconciliation.
• Reduce excess inventory, shortages, material losses and working-capital blockage in coordination with procurement and finance.

6. Preventive & Breakdown Maintenance

• Establish preventive and predictive maintenance schedules for machinery, utilities and critical equipment.
• Track equipment availability, breakdown frequency, mean time to repair and mean time between failures.
• Coordinate breakdown analysis, spare-parts planning, maintenance records and reliability improvement initiatives.
• Promote safe maintenance practices and minimise unplanned downtime.

7. Costing & Bill of Materials (BOM) Analysis

• Review product costing, material consumption, yield, scrap, conversion costs and process losses.
• Validate BOMs, standard consumption and routing/process data with relevant departments.
• Identify cost-reduction opportunities without compromising quality, safety or customer requirements.
• Support variance analysis and periodic reviews of actual versus standard costs.

8. Team & Process Management

• Lead, coach and develop production, planning, quality and maintenance personnel within the assigned scope.
• Define standard operating procedures, work instructions, accountability and performance measures.
• Build a culture of discipline, ownership, safety, collaboration and continuous improvement.
• Coordinate cross-functional reviews and ensure timely closure of action items.

9. Lean Manufacturing & Continuous Improvement

• Implement practical Lean tools such as 5S, Kaizen, Poka-Yoke, 7 QC tools, visual management and standard work.
• Identify and eliminate waste, bottlenecks, avoidable movement, waiting time, defects and excess processing.
• Use data to improve productivity, first-pass yield, equipment effectiveness, delivery performance and cost.
• Track improvement projects and quantify benefits achieved.

Educational Qualifications

• Essential: B.E. / B.Tech in Mechanical Engineering, Production Engineering, Industrial Engineering, Metallurgical Engineering or Materials Science.
• Preferred for copper and non-ferrous metal operations: Metallurgical / Materials Engineering or Mechanical Engineering with relevant metal-processing experience.
• Diploma holders with an exceptional and demonstrably relevant manufacturing track record may be considered, but a bachelors degree is preferred for this role.
• Value-added qualifications: Postgraduate Diploma / MBA in Operations or Supply Chain Management; certifications or formal training in Lean, Six Sigma, IATF 16949, ISO systems, internal auditing, TPM or quality tools.

Preferred Industry Background

Copper and non-ferrous metal manufacturing or processing is strongly preferred. Candidates from metal fabrication, extrusion, rolling, drawing, foundry, automotive components, electrical conductors, industrial engineering or other process-driven manufacturing industries may also be suitable if they have relevant operational and quality-system experience.

Key Skills & Competencies

• Strong shop-floor leadership and structured problem-solving ability.
• Working knowledge of production planning, process control, quality tools, maintenance systems and inventory practices.
• Ability to interpret operational data and build practical KPI dashboards using Excel or ERP/MRP systems.
• Experience with ERP systems and manufacturing documentation; SAP experience is an advantage.
• Clear communication, cross-functional coordination, people development and change-management skills.
• A practical, safety-conscious and results-oriented approach to improving quality, productivity, delivery and cost.

Indicative Performance Measures (KPIs)

• Production plan adherence and on-time delivery.
• Productivity, capacity utilisation and equipment downtime.
• First-pass yield, rejection, rework, scrap and customer complaints.
• Inventory accuracy, WIP levels and finished-goods ageing.
• Preventive maintenance compliance and repeat breakdowns.
• Cost variance, material yield and measurable cost savings.
• Audit findings, corrective-action closure and safety compliance.
• Completion and verified impact of Lean / Kaizen improvement projects.