Plant Controller

We are looking for a Plant Controller with strong engineering knowledge, analytical ability, and a systematic approach. The ideal candidate enjoys working with data, systems, and different teams to improve plant performance.

This role involves production planning, process optimization, cost control, and overall operational management to ensure the plant runs efficiently, consistently, and in line with business goals and safety standards.

Key Responsibilities

Production Planning & Control

• Develop data-driven production schedules in alignment with demand forecasts, inventory targets, and raw material availability.
• Track daily production performance and ensure adherence to planned targets on output, quality, and cost.
• Proactively identify and address operational bottlenecks using analytical and engineering insights.
• Maintain oversight of multiple product lines, optimizing batch sequencing, equipment utilization, and resource allocation.

Data-Driven Operations

• Build dashboards and monitoring tools for key parameters such as yield, cycle time, downtime, and resource efficiency.
• Analyze plant data to identify deviations or inefficiencies and recommend engineering-based corrective actions.
• Establish and track performance KPIs, enabling management to make informed, data-backed operational decisions.
• Lead digital initiatives to enhance real-time visibility and traceability of production metrics.

Process & Engineering Support

• Support process design, modification, and scale-up activities in coordination with R&D and project engineering teams.
• Lead or assist in implementation of process improvement, debottlenecking, and cost-reduction projects.
• Ensure all process documentation (mass balance, PFDs, P&IDs, SOPs, etc.) remains accurate and updated.
• Champion process safety and ensure strict adherence to HAZOP recommendations, operating limits, and EHS standards.

Operational Excellence

• Drive continuous improvement through Lean, Six Sigma, or other structured methodologies.
• Collaborate with maintenance and utility teams to improve equipment reliability, uptime, and energy efficiency.
• Standardize workflows, reduce variability, and promote best practices across the plant
• Benchmark plant performance with industry standards to identify areas for improvement.
• Promote a culture of accountability, safety, and discipline in operations.

Financial & Cost Control

• Monitor production costs, yields, and consumption patterns to ensure cost competitiveness.
• Analyze variances in raw material usage, utilities, and conversion costs to support financial reporting.
• Collaborate with finance and procurement to prepare and review plant budgets.
• Drive initiatives to reduce waste, improve yield, and enhance overall profitability.

Compliance & Safety

• Ensure all operations comply with statutory, environmental, and safety regulations.
• Support audits (ISO, GMP, EHS, customer, or regulatory) through accurate data and documentation.
• Drive root cause analysis and corrective action for any safety or quality incidents.

Cross-Functional Leadership

• Work closely with production, quality, procurement, and management teams to align plant priorities.
• Serve as the central point for operational data, reporting insights, and driving accountability across teams.
• Contribute actively to plant-level reviews and improvement initiatives.

Qualifications:

• Education:

• Bachelors degree in Chemical Engineering from a reputed engineering institution.

• Postgraduate qualification in Operations, Industrial Engineering, or Management will be an advantage.

• Experience:

• 810 years of experience in a chemical or process manufacturing environment.

• Exposure to batch operations, production planning, and data-based performance analysis.

• Technical Competencies:

• Strong understanding of process design, thermodynamics, mass balance, and plant operations.

• Proficiency in data analysis tools such as Excel, Power BI, or equivalent platforms.

• Familiarity with ERP or MES systems; experience in process simulation tools (Aspen Plus, ChemCAD) is a plus.

• Behavioral Competencies:

• Analytical and data-oriented mindset.

• Strong interpersonal and communication skills.
• Structured problem solver with a continuous improvement attitude.
• Ability to collaborate across departments and influence outcomes through data and logic.

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