Plant Cost Controller

Job Description

1. • Location: Plant
   • Department: CFO/ Head of Finance (with plant coordination)
   • Company: Cosmos Pumps Pvt. Ltd.

2. 2. Role Summary:

We are looking for a Plant Cost Controller who own cost accuracy, inventory integrity, BOM correctness, vendor cost cycles, and order/product-level margins at the plant level, ensuring that every rupee of cost is traceable, controllable, and improvable before it reaches financial book

3. Core Responsibilities

4. • Cost & BOM (Plant-Level): Own BOM accuracy for all SKUs in coordination with Design, Engineering & Production and track incorrect pricing assumption
   • Order-wise & Product (SKU)-wise Margin Control
     • Flag loss-making orders
     • warranty and quality cost control
   • Inventory & WIP Control (Physical + System)
     • Slow-moving and non-moving items
     • Excess safety stock driven by poor planning
     • Ensure physical flow matches system flow
   • Vendor Cost & Procurement Cycle Analysis
     • Track vendor-wise cost trends for key materials
     • Support purchase negotiations with cost breakdowns
     • Validate landed cost assumptions used in pricing
   • Variance Analysis → Corrective Action
     • Standard vs actual variance split into:
       • Price variance
       • Usage variance
       • Yield loss
       • Process inefficiency
     • Lead joint reviews with Production, Stores, QA
     • Convert variance into:
       • BOM changes
       • Process improvements
       • Vendor switches
       • Pricing corrections
   • Pricing Support (Cost-Truth Provider)
     • Validate quotations for:
       • Custom products
       • One-time orders
       • Export / special terms orders
     • Ensure pricing reflects:
       • True conversion cost
       • Yield realities
       • Inventory holding impact
   • Factory Overhead Cost Control (Explicit Ownership)
     • Own identification, classification, and allocation logic of factory overheads, including:
       • Power & fuel
       • Repairs & maintenance
       • Consumables
       • Indirect manpower
       • Utilities
     • Define and periodically validate overhead absorption rates:
       • Machine hour based
       • Labour hour based
       • Activity-based (where relevant)
     • Identify root causes for overhead inflation:
       • Low capacity utilization
       • Inefficient batch sizes
       • Idle time
     • Work with Plant Head to convert overhead insights into:
       • Capacity planning changes
       • Batch optimization
       • Make vs buy decisions
   • Labour Cost & Productivity Control (Direct + Indirect)
     • Own labour cost per unit / per order / per SKU
     • Track and analyse:
       • Direct labour productivity
       • Overtime trends
       • Contract labour dependency
       • Skill mismatch and learning curve losses
     • Validate standard labour hours in routing vs actuals
     • Highlight labour-driven margin erosion in:
       • Low-volume orders
       • Customised products
     • Support decisions on:
       • Automation vs manual
       • Line balancing
       • Shift planning from a cost lens

Skills and Qualifications

5. Qualification & Experience:

6. • CMA with costing background
   • 3–8 years in manufacturing industry
   • Strong SAP & Excel skills

7. Skills Required:

8. • Cost accounting, margin analysis
   • Manufacturing cost control & inventory management
   • Strong analytical and coordination skills
   • Ability to work in a fast-paced production environment.