Head - Production Planning & Control - Textile Industry

Position: "Production Planning and Control (PPC)" for a textile mill having bow room , spinning , weaving , knitting , process and dye house , printing house

Company Background: SRN / NYTIL is composite textile MILL having blow room, spinning , weaving , knitting , process house with dyeing / Printing facilities and garmenting unit as well.

Functional:

v Dynamic , result oriented textile professional having hands of experience of PPC in composite textile mill.

v Should have competencies & knowledge of Spinning , Weaving , Pre-treatment, Dyeing, Printing , Finishing of various Woven" and "knitted" fabrics of various blends including 100% Cotton, 100%Polyester, Blends of Polyester+Cotton , Polyester+Viscose, 100% polyester texturized, Yarn Dyed fabrics etc.

v Must have worked in SAP environment in textile Mill.

Technical Skills :

v Must poses full technical knowledge and experience of composite textile mill raw materials and finished products :

v Textile Machines / Equipments / Raw Materials

v Dyes and Chemicals : Must poses thorough knowledge various types of dyes for Dyeing + printing ( Disperse, Vat , Reactive, Sulphur, Direct etc.) Various Auxilaries , processing, finishing, Coating, Waterproofing Chemicals and agents etc

- Thorough knowledge and experience of SAP Production Planning Module

Functional Responsibilities :

1) Develop and implement production plans to meet customer demands while optimizing resources.

- Preparation of daily, weekly, monthly and Yearly plans for production as per the order book.

2) Coordinate with sales, marketing, and production teams to gather input for production schedules.

- Analyze production specifications and capacity data to create feasible and efficient production schedules.

- Understanding the MTO and MTS based orders and planning accordingly.

3) Preparation of capacity planning and understanding the gaps between the requirements and capacity.

- Managing capacity for each of the department (Spinning, Weaving, Knitting, Sweater plant, Cotton wool plant, Wet processing and Garments).

- Working on yearly Sales forecast.

- Understanding the sales season and sales cycle

4) Monitor and track raw material availability and coordinate with procurement for timely material procurement.

Ordering of the raw materials based on sales forecast, stocks and the lead times.

5) Understanding the product and the customer requirement to ensure the delivery of the required product on time.

- Coordinating with the production team and the sales team to ensure the delivery of the correct product.

- Maintaining the order book and the production statuses for all the orders including the requirement of the semifinished products.

6) Creating of Various Material Masters , production Masters, Creating Production orders & BOMS in SAP including routing of production orders.

7) Monitoring the production reports and variances if any and ensuring the production as per the production plan.

- Ensuring the availability of raw material as per the production plan

8) Collaborate with maintenance and quality control teams to ensure smooth production processes.

9) Implement and maintain systems for real-time production tracking and reporting.

10) Conduct regular reviews of production performance and adjust plans as needed.

11) Optimize inventory levels to balance between production efficiency and cost control.

12) Identify bottlenecks and implement solutions to improve production flow.

13) Keep abreast of industry trends and technology to enhance production planning processes.

ERP SAP system Related Responsibilities:

A) Utilize SAP ERP system to create and maintain production plans aligned with business goals.

- Ensuring the planning activities and the orders released in SAP as per the requirement and the plan.

B) Ensuring the availability of the correct master data in the SAP before providing the production orders.

C) Collaborate with cross-functional teams to integrate production planning data into the SAP system.

D) Ensure accurate and real-time data entry into the SAP system for production-related transactions.

- Ensuring the planning, releasing, monitoring, rescheduling, updating and closure of the assigned production orders.

E) Generate reports and analytics from SAP to support decision-making in production planning.

F) Collaborate with IT teams to troubleshoot and resolve SAP-related issues affecting production.

G) Train and support production teams in utilizing SAP functionalities for day-to-day operations.

H) Implement SAP best practices for production planning, ensuring alignment with industry standards.

I) Work closely with SAP consultants to customize and enhance the SAP ERP system for the textile mill's needs.

Key Performance Areas (KPAs):

1. Production Efficiency: Ensure optimal utilization of resources to achieve production targets.

2. Customer Satisfaction: Meet delivery timelines and adhere to customer specifications.

3. Inventory Management: Maintain appropriate levels of raw materials and finished goods.

4. Cost Control: Implement measures to reduce production costs without compromising quality.

5. Process Improvement: Continuously identify and implement process improvements in production planning and control.

6. Communication and Collaboration: Foster effective communication and collaboration between different departments.

Key Result Indicators (KRIs):

1. On-time Delivery Rate: Percentage of orders delivered on or before the promised date.

2. Production Yield: Ratio of actual output to the planned output.

3. Inventory Turnover: Number of times inventory is sold and replaced in a given period.

4. Resource Utilization: Measure of how efficiently resources (labor, machines) are utilized.

5. Production Planning Accuracy: Percentage of production plans executed as per schedule.

6. Cost per Unit Produced: Measure of production cost efficiency.

7. Bottleneck Resolution Time: Time taken to identify and resolve production bottlenecks.

8. Customer Complaints: Number of customer complaints related to production delays or quality issues.

SAP / System Related Key Performance Areas (KPAs):

1. SAP Integration: Ensure seamless integration of production planning data into the SAP system.

2. Data Accuracy: Maintain high levels of accuracy in SAP data entry and transactions.

3. SAP Configuration: Optimize SAP modules for efficient production planning and control.

4. User Training: Train production teams to effectively use SAP functionalities for their roles.

5. Process Automation: Identify opportunities for process automation within the SAP system.

6. SAP Security: Ensure data security and user access control within the SAP environment.

7. Timely Reporting: Generate and distribute production-related reports in a timely manner.