Project Controller / Manager | Cement Industry | Big4 Consulting | Andra Pradesh/ Karnataka-

Job Description: Project Controller / Project Manager

Experience: 7–12 Years

Client : Big4 Consulting

Industry: Integrated Cement Plant / Heavy Process Industry (Cement, Metals, Power,

Mining, EPC)

Location: Andhra Pradesh / Karnataka

Function: Projects / Capex / Engineering

Role Overview

The Project Controller / Project Manager is responsible for end-to-end execution and

control of capital projects, ensuring delivery within approved cost, schedule,

quality, and safety standards. This role combines project management leadership

with strong project controls expertise, driving successful execution of plant

expansions, upgrades, and greenfield/brownfield projects.

Key Responsibilities

1. Project Leadership & Execution

 Lead end-to-end project management from concept to commissioning

 Manage capex projects (plant expansion, kiln upgrades, grinding units, WHR

systems, etc.)

 Define project scope, execution strategy, and implementation plans

 Ensure alignment with business objectives and investment approvals

2. Planning & Scheduling

 Establish integrated master project schedules using Primavera P6 / MS Project

 Develop detailed WBS, timelines, and resource plans

 Monitor schedule performance and implement recovery plans for delays

 Ensure coordination between engineering, procurement, and construction

3. Cost Management & Control

 Develop and manage project budgets, cost baselines, and forecasts

 Track commitments, cash flow, and actual expenditures

 Implement cost control systems and variance analysis (CPI/SPI)

 Identify cost risks and drive optimization initiatives

4. Project Controls & Performance Monitoring

 Implement advanced project control frameworks (EVM, dashboards, KPIs)

 Provide accurate progress tracking (physical & financial)

 Deliver management reports including:

o Weekly / Monthly MIS

o Progress dashboards

o Risk and variance reports

5. Contract & Procurement Management

 Lead or support contracting strategy and vendor selection

 Manage EPC/PMC contractors and ensure contractual compliance

 Review and certify contractor bills, claims, and variation orders

 Handle contract disputes and claims management

6. Risk & Change Management

 Establish and maintain risk register and mitigation plans

 Manage change requests, scope variations, and approvals

 Conduct impact assessments on cost and schedule

 Ensure proactive escalation of critical risks

7. Stakeholder Management

 Act as key interface between:

o Senior leadership

o Technical teams

o Contractors/consultants

o Plant operations

 Lead project review meetings and steering committees

 Ensure cross-functional coordination

8. Construction & Site Execution (if applicable)

 Oversee site execution, erection, and commissioning activities

 Ensure adherence to quality, safety, and timelines

 Support troubleshooting and issue resolution during execution

9. Governance, Compliance & Documentation

 Ensure adherence to:

o Company project governance frameworks

o Statutory & regulatory requirements

o Safety & environmental standards

 Maintain proper project documentation and audit readiness

Key Requirements

Education

 Bachelor’s Degree in Engineering (Mechanical / Civil / Electrical)

 MBA / PMP / Prince2 certification preferred

Experience

 7–12 years in project management / project controls

 Strong experience in:

o Integrated cement plants (kiln, clinker, grinding units)

o Large-scale Capex / EPC projects

 Proven track record of handling projects > ₹100–500 Cr (or equivalent)

Core Competencies

Technical Skills

 Strong proficiency in:

o Primavera P6 / MS Project

o SAP / ERP systems

o Advanced Excel, Power BI (preferred)

 Deep knowledge of:

o Project planning & scheduling

o Earned Value Management (EVM)

o Cost control & forecasting

o Contract management

Leadership & Behavioral Skills

 Strong leadership and team management capability

 Excellent stakeholder communication and influencing skills

 Strategic thinking and decision-making under uncertainty

 High ownership, accountability, and execution focus

Key Performance Indicators (KPIs)

 Project completion within budget and timeline

 Schedule performance (SPI) and cost performance (CPI)

 Forecast accuracy and variance management

 Contractor performance and contract compliance

 Safety and quality adherence

Preferred Experience

 Greenfield / brownfield cement plant projects

 Kiln line installation, capacity expansion, WHR systems

 EPC project environment or PMC role

 Multi-location or large team management