Plant Controller

Plant Controller

production planning, process optimization, cost control, and overall operational management

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.

Apply

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