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Job Overview:
The Production Planning Engineer will be responsible for designing, implementing, and optimizing manufacturing processes to drive operational efficiency, reduce waste, and ensure timely production. This role requires a hands-on approach to process analysis, production/capacity planning, and cross-functional collaboration with design engineering, CI engineers, quality, and supply chain teams. The ideal candidate will have a deep understanding of Lean and Six Sigma methodologies, a keen eye for detail, and experience in high-volume production environments. Success in this role will be measured by improvements in cycle time, productivity, cost reduction, throughput, and product quality.
Key Responsibilities:
Production Planning & Scheduling:
- Develop, maintain, and adjust short- and long-term production schedules based on order forecasts, inventory levels, and labor availability.
- Coordinate with procurement and supply chain to ensure materials are available for production, aligning schedules to prevent disruptions.
- Collaborate with production supervisors and floor teams to adjust schedules dynamically in response to unplanned events, equipment downtime, or staffing shortages.
Process Optimization & Continuous Improvement:
- Conduct time studies, workflow analyses, and bottleneck assessments to identify areas for efficiency gains and waste reduction.
- Apply Lean principles (6S, Kaizen, Value Stream Mapping) to streamline processes and enhance productivity.
- Lead and participate in cross-functional Kaizen events and continuous improvement projects, developing actionable recommendations and implementing process changes to achieve measurable results.
- Perform process capability analysis.
Capacity Planning & Resource Allocation:
- Evaluate plant capacity and equipment utilization regularly to ensure the ability to meet production demands without overextending resources.
- Recommend adjustments to staffing levels, shift configurations, and machine usage to optimize throughput and balance workload.
- Develop and maintain capacity models to anticipate production constraints, both for short-term fluctuations and long-term growth.
Inventory & Material Management:
- Work with inventory control and materials teams to develop inventory policies, reorder points, and safety stock levels based on demand patterns and lead times.
- Monitor and report on inventory levels, identifying excess stock or shortages, and implementing strategies to improve inventory turnover and reduce carrying costs.
- Support material planning efforts by coordinating Kanban or Vendor Managed Inventory (VMI) initiatives where applicable.
Cost Analysis & Efficiency Tracking:
- Conduct detailed cost analyses for production processes, considering material, labor, equipment, and overhead costs.
- Develop and implement cost-saving strategies through process redesign, waste reduction, and improved resource allocation.
- Track performance metrics (KPIs) such as cycle time, yield, and defect rates, using data to drive continuous improvement efforts.
Cross-Functional Collaboration & Communication:
- Serve as a liaison between production, quality, engineering, and supply chain teams to resolve issues, improve product flow, and support new product introductions.
- Actively participate in project teams, contributing technical insights and feasibility assessments for design changes, product modifications, or equipment upgrades.
- Lead regular meetings to review production progress, address challenges, and align cross-functional priorities.
Technical Documentation & Standardization:
- Create and maintain accurate technical documents, including process maps, Standard Operating Procedures (SOPs), and work instructions to ensure consistent and efficient manufacturing practices.
- Develop daily standard work routines and performance tracking for shop floor staff to support process consistency and operational excellence.
- Ensure all technical documentation aligns with quality standards, regulatory requirements, and company policies.
- Collaborate closely with design engineering to integrate design specifications, improvements, and updates into technical documentation, ensuring manufacturing processes reflect the latest engineering developments.
Quality Assurance & Compliance:
- Work closely with the Quality team to address quality issues promptly, using root cause analysis (e.g., Fishbone, 5 Whys) to prevent recurrence.
- Ensure compliance with relevant industry standards and regulatory requirements (e.g., ISO, OSHA), conduct safety audits and supporting corrective actions where needed.
- Drive process improvements focused on defect reduction, enhanced quality control, and adherence to quality standards.
Training & Development:
- Train production staff on new or revised processes, ensuring they understand operational changes and safety procedures.
- Develop training materials and conduct hands-on workshops to upskill teams in Lean principles, quality standards, and best practices.
Qualifications:
- Education: Bachelor’s degree in Industrial Engineering, Manufacturing Engineering, or related field; Master’s degree or relevant certification is a plus.
- Experience: Minimum of 5 years in manufacturing planning, production engineering, or a similar role within a low mix high-volume manufacturing environment. Experience in [specific industry, e.g., automotive, aerospace, fabrication] is preferred.
Technical Skills:
- Proficiency with ERP/MRP systems (e.g., SAP, Oracle, Epicor) for production planning and inventory management.
- Strong analytical skills with proficiency in data analysis tools (e.g., Excel, Minitab, Power BI) and ability to create and interpret process flow diagrams and statistical charts.
- Familiarity with CAD software and other design tools is a plus.
- Experience with development of Bills of Material and Method of Manufacturing/Routings.
- Lean/Continuous Improvement: Proven knowledge of Lean manufacturing principles and Six Sigma methodologies. Certification (e.g., Lean Six Sigma Green/Black Belt) is preferred.
- Communication Skills: Excellent verbal and written communication skills, with an ability to present findings and recommendations to leadership and collaborate effectively with cross-functional teams.
- Problem-Solving: Strong troubleshooting skills with experience in root cause analysis and corrective action planning.
Working Conditions:
- Primarily office-based with frequent visits to the production floor.
Pay: $90,000.00-$125,000.00 per annum
