Senior Engineer/Assistant Manager/Deputy Manager - PPC

Role & responsibilities

The Assistant Manager PPC is responsible for end-to-end production scheduling, machine capacity planning, raw material availability and shop-floor execution tracking across thermoplastic injection molding and assembly lines.

This role ensures maximum machine utilization, minimizes mold changeover downtime, controls WIP/FG inventory levels and delivers 100% On-Time In-Full (OTIF) dispatches, with a primary focus on Electrical Switchgear components, as well as automotive and industrial product lines.

Key Responsibilities & Deliverables

• Formulate Master Production Schedules (MPS) and detailed daily/weekly shift-wise machine-loading plans based on sales orders, customer forecasts, and delivery priorities.
• Allocate jobs across injection molding machines (50T to 650T) based on mold compatibility, platen size, tonnage, and cycle time parameters.
• Sequence production to minimize setup and mold changeover downtime (applying SMED principles) and avoid excessive color/material change purge losses.
• Plan and balance production runs for multi-component kits, insert-molded parts, and sub-assembly requirements for switchgear products.
• Plan and track availability for engineering plastics, flame-retardant (FR/V-0) resins, and commodity polymers (PA6/PA66, PBT, PC, ABS, POM, PP), masterbatches, metal inserts, and packaging materials.
• Coordinate with Purchase, Stores, and Quality Assurance to ensure raw materials are cleared through inward inspection (GRN/IQC) well ahead of production schedules.
• Manage regrind/reprocessed material blending within approved customer tolerances while keeping regrind inventory in check.
• Maintain optimum Min-Max inventory levels across RM, WIP, and FG to prevent line stoppages while keeping inventory carrying costs lean.
• Partner with the Tool Room to align mold availability, scheduled preventive maintenance (PM), mold refurbishments, and new tool trials (T0, T1, PPAP validation runs).
• Ensure critical auxiliary units (dehumidifier dryers, Mold Temperature Controllers (MTC), hot runner controllers, and robotic pickers) are staged and aligned with machine allocations.
• Track daily actual output against the planned schedule, investigate root causes of variances (breakdowns, cycle time lags, quality rejections), and execute immediate recovery plans.
• Monitor Overall Equipment Effectiveness (OEE), machine availability, scrap percentage, and downtime metrics.
• Coordinate with Dispatch and Logistics teams to ensure finished goods are cleared, packed, and shipped to meet OTIF delivery commitments.
• Maintain and audit Bills of Materials (BOM), production routings, and standard cycle times in the ERP/SAP system.
• Drive shop-floor operational discipline, supporting 5S, Kaizen, Lean manufacturing, and waste reduction initiatives.
• Prepare and present daily/monthly MIS reports: Daily Production Report (DPR), Machine Utilization, Plan vs. Actual Variance, Scrap Analysis, and Customer OTIF.

Preferred candidate profile

• Education: B.Tech / B.E. / Diploma in Mechanical, Plastics Engineering (CIPET), or Production Engineering.
• Experience: 6 to 10 years of hands-on PPC experience in Plastic Injection Molding plants, with a strong preference for candidates handling components for Electrical Switchgears (MCBs, MCCBs, contactors, electrical enclosures) or precision engineering assemblies.
• Technical Skills:
• Hands-on expertise in ERP/SAP (PP/MM modules).
• Strong working knowledge of engineering plastics (PA6, PA66, PBT, PC-FR) and insert molding.
• Practical understanding of mold changeover optimization (SMED), OEE tracking and inventory control.
• Soft Skills: Strong cross-functional coordination, quick crisis management and data-driven analytical skills.