Role & responsibilities
1. Plant Costing & Product Costing
- Manage the end-to-end costing of plant operations and products.
- Prepare and maintain product-wise cost sheets.
- Calculate material, labour, power, fuel, consumables, overheads, processing costs, and other manufacturing costs.
- Maintain standard costing and periodically update costs based on changes in material prices, processes, utilities, and overheads.
- Analyse the impact of changes in raw-material prices, production volumes, process changes, and other cost drivers.
2. Variable Costing & Analysis
- Monitor and analyse variable costs on a product-wise and plant-wise basis.
- Track major variable cost components such as:
- Raw materials
- Packaging materials
- Power & fuel
- Consumables
- Direct labour
- Process losses / wastage
- Job work / subcontracting
- Other variable manufacturing expenses
- Prepare monthly variable-cost reports and explain major deviations from standard/budget costs.
- Conduct cost-driver analysis and identify areas of cost improvement.
3. BOM & Cost Sheet Management
- Prepare, verify, and maintain Bill of Materials (BOM) for all products/SKUs.
- Ensure BOM accurately reflects actual production processes and material consumption.
- Calculate BOM-based product costing.
- Coordinate with Production/Engineering teams for changes in BOM, process routes, yields, and material consumption.
- analyse the financial impact of BOM and process changes.
4. Variance Analysis
- Conduct actual vs. standard/budget cost variance analysis.
- analyse variances related to:
- Material price
- Material consumption
- Production yield
- Wastage/scrap
- Labour
- Power & fuel
- Production volume
- Overheads
- Purchase price
- Prepare monthly variance reports with clear explanations and actionable insights.
- Highlight abnormal cost movements to management.
5. Cost Control & Cost Reduction
- Identify opportunities for cost reduction and process improvement.
- Work with cross-functional teams to identify excessive consumption, wastage, inefficiencies, and cost leakages.
- Track cost-saving initiatives and quantify their financial impact.
- Develop cost benchmarks for products/processes wherever required.
6. MIS & Management Reporting
- Prepare regular plant costing MIS and management reports.
- Develop dashboards/reports covering:
- Product-wise cost
- Variable cost per unit
- Material consumption
- Conversion cost
- Production cost
- Standard vs. actual cost
- Cost variance
- Cost per kg/unit
- Yield and wastage
- Provide meaningful analysis and recommendations to Plant and Finance management.
7. Budgeting & Forecasting
- Support preparation of annual plant budgets and cost standards.
- Prepare cost forecasts based on production plans, raw-material prices, utilities, manpower, and other cost assumptions.
- Monitor actual performance against budget and forecast.
8. Cross-Functional Coordination
- Coordinate with Purchase, Stores, Production, PPC, Engineering, Maintenance, Quality, Sales, and Finance teams for accurate costing data.
- Validate consumption and operational data used for costing.
- Participate in new-product development and provide cost estimates for new products/processes.
Key Deliverables / KPIs
- Accuracy and timeliness of product costing.
- Accuracy and maintenance of BOMs.
- Monthly variable-cost analysis.
- Actual vs. standard cost variance reporting.
- Identification and tracking of cost-reduction opportunities.
- Accuracy of plant cost budgets and forecasts.
- Reduction in unexplained cost variances.
- Timely submission of plant costing MIS.
- Improvement in material yield and reduction in wastage/cost leakages.
Required Skills
- Strong knowledge of manufacturing costing and cost accounting.
- Good understanding of BOM, standard costing, variable costing, and variance analysis.
- Strong Excel skills, including Pivot Tables, VLOOKUP/XLOOKUP, SUMIFS, Power Query, and basic data analysis.
- Experience with ERP systems such as SAP / Oracle / Microsoft Dynamics / Tally will be preferred.
- Strong analytical and problem-solving skills.
- Ability to work with large volumes of operational and financial data.
- Good understanding of manufacturing processes and cost drivers.
- Strong communication and coordination skills.