Plant Controller

Job Function/Purpose

We are seeking an experienced Plant Controller to lead financial controlling and manufacturing cost management activities of our New Jersey operation. This is a hands-on, highly operational, and analytical role, requiring someone who is comfortable working directly on the plant floor and partnering closely with Operations, Engineering, Quoting, Supply Chain, and Finance.

The Plant Controller will play a critical role in Falcon’s transformation from manual processes and limited manufacturing cost visibility to a more structured, data-driven, and professionally managed manufacturing operation, while improving systems, processes, costing discipline, and operational accountability. The Plant Controller will initially work with a significant amount of operational and manual data, using Excel, while progressively helping the organization transition towards stronger ERP-based processes.

The ideal candidate should have proven experience in ideally within metal fabrication, metalworking, fixtures, displays, industrial manufacturing or similar operations, and be comfortable operating in an environment where processes are not fully developed.

Immediate or short-notice availability preferred, with the goal of being fully onboarded by early November 2026.

Key Responsibilities

Manufacturing Cost Control

• Own and continuously improve the plant's manufacturing cost control processes.
• Analyze actual production costs against quotations, standards, budgets and expectations.
• Monitor and analyze: direct labor costs, labor hours and productivity, material consumption, material purchase price variances, scrap and waste, production efficiencies, outsourcing costs, freight and other production-related costs, manufacturing overhead absorption.
• Identify cost deviations at job, project, and product level.
• Work with Operations, Engineering and Quoting teams to understand the root causes of deviations.
• Develop corrective actions and follow up on implementation.
• Provide visibility into the true contribution margin and profitability of individual projects and customers.

Job Costing & Project Tracking

• Establish and maintain strong interim controls and develop Excel-based job-costing and project-tracking tools while the ERP environment is improved.
• Track estimated versus actual of materials, labor hours and cost, purchased components, subcontracting, freight, and other manufacturing costs.
• Partner with the Quoting and Estimating to compare quoted costs against actual production results.
• Create feedback loops between actual production results and future quotations.
• Identify systematically under- or overestimated cost assumptions.
• Support management in understanding project profitability.

Inventory Control & Physical Inventory

• Establish and strengthen inventory controls for raw materials, work in process, finished goods, scrap, and obsolete or slow-moving inventory.
• Oversee inventory valuation, material receipts, transfers, consumption, and reconciliations between physical inventory and accounting records.
• Investigate inventory variances and improve inventory accuracy, reporting, ownership, and accountability.
• Lead the year-end physical inventory process, including:

o Designing the inventory count methodology and procedures.

o Preparing the plant for the physical inventory.

o Establishing inventory counting teams and responsibilities.

o Implementing inventory tags/count sheets and control procedures.

o Coordinating count instructions and training.

o Supervising the physical count.

o Performing recounts and variance analysis.

o Reconciling the physical inventory with accounting records.

o Supporting external auditors during inventory observation.

o Preparing recommendations following the count to improve ongoing inventory controls

ERP & Systems Transformation

• Support the transition from Sage to Epicor, with a focus on manufacturing costing, inventory management, and financial controls.
• Document current manufacturing, costing, and inventory processes, identify gaps, and define future requirements for manufacturing costing and inventory management.
• Partner with Finance, Operations, Engineering, IT, and external implementation partners on system configuration, testing, data migration, inventory reconciliation, and implementation.
• Establish and document effective operating procedures and controls within Epicor and support user training.
• Help establish a reliable perpetual inventory environment with appropriate controls over material movement and consumption.

Financial & Operational Analysis

• Support the US Finance Director with monthly financial reporting, plant performance analysis, budgeting, forecasting, and financial close activities.
• Prepare plant financial reporting, dashboards, and KPIs covering productivity, costs, inventory, manufacturing variances, and operational performance.
• Analyze and explain manufacturing cost movements, trends, and variances to management.
• Improve monthly closing procedures related to inventory, cost of goods sold (COGS), work in process, manufacturing variances, accruals, capital expenditures, etc. to support informed plant-level decision-making.

Capital Investment & Business Analysis

• Evaluate and develop financial business cases for new equipment, automation, and other capital investments.
• Analyze investment costs, labor savings, productivity improvements, capacity increases, outsourcing reductions, maintenance, working capital, payback, ROI, and cash flow impacts.
• Partner with Operations and Engineering to evaluate and prioritize investments and perform post-investment analysis.
• Support management decisions regarding automation and manufacturing efficiency.

Cross-Functional Partnership

• Maintain a highly visible, hands-on presence within the plant and develop a strong understanding of manufacturing processes, workflows, and cost drivers.
• Partner with Operations, Engineering, Quoting/Estimating, Supply Chain, Purchasing, Production, Finance, and Senior Management to improve operational and financial performance.
• Challenge assumptions, identify opportunities for improvement, and promote a culture of cost awareness, accountability, and continuous improvement.