Key Responsibilities and Required Skills for a Flow Controller

🎯 Role Definition

As a Flow Controller, you are the central nervous system of our operations, ensuring the smooth, efficient, and timely movement of materials, products, and information from point of origin to point of consumption. You will be the go-to expert for monitoring workflows, anticipating and resolving bottlenecks, and coordinating between production, warehousing, and shipping departments. This pivotal role requires a sharp eye for detail, a proactive mindset, and the ability to make quick, informed decisions to keep our supply chain optimized and our operational targets on track. If you thrive in a dynamic environment and are a master of orchestration, this is the opportunity for you.

📈 Career Progression

Typical Career Path

Entry Point From:

Logistics Coordinator
Production Planner
Inventory Analyst

Advancement To:

Supply Chain Manager
Logistics Manager
Operations Supervisor

Lateral Moves:

Supply Chain Analyst
Procurement Specialist

Core Responsibilities

Primary Functions

Proactively monitor and manage the end-to-end flow of materials, from raw material receipt through all production stages to finished goods shipment, ensuring a seamless process.
Utilize ERP systems (e.g., SAP, Oracle) and Warehouse Management Systems (WMS) to track order statuses, inventory levels, and production schedules in real-time.
Identify, analyze, and resolve potential and actual bottlenecks in the production line or logistics network to prevent delays and maintain throughput.
Act as the primary point of contact between production, planning, quality control, and warehouse teams to ensure clear communication and alignment on priorities.
Expedite and prioritize critical orders based on customer requirements, material availability, and production capacity, making adjustments as needed.
Continuously evaluate and manage inbound and outbound logistics traffic, coordinating with carriers and freight forwarders to optimize dock schedules and minimize wait times.
Generate and analyze daily/weekly performance reports and KPIs related to on-time delivery, production attainment, and workflow efficiency.
Manage and troubleshoot exceptions in the workflow, such as material shortages, equipment downtime, or quality holds, by developing and executing recovery plans.
Ensure the accuracy of system data by performing regular audits and reconciling discrepancies between physical inventory and system records.
Coordinate the flow of "hot parts" or urgent materials within the facility, ensuring they reach their destination without disrupting the standard workflow.
Participate in daily production meetings to provide updates on flow status, highlight risks, and collaborate on solutions with cross-functional leaders.
Analyze production capacity and workload to provide data-driven recommendations for labor allocation and resource management to supervisors.
Oversee the release of production orders to the floor, ensuring that all necessary components, tooling, and documentation are available.
Communicate directly with customer service or account managers regarding the status of high-priority orders and potential impacts on delivery dates.
Facilitate the efficient movement of goods between different manufacturing cells, departments, or buildings within a large campus.
Monitor adherence to the master production schedule (MPS) and escalate deviations to the planning team for immediate review and action.
Champion lean manufacturing and continuous improvement principles by identifying and helping to implement process changes that reduce waste and improve flow.
Manage the reverse logistics flow, including customer returns and the disposition of non-conforming materials, ensuring they are processed efficiently.
Coordinate with the procurement team to ensure timely delivery of raw materials and components, mitigating risks of stockouts.
Develop contingency plans for common disruptions to ensure operational resilience and a swift return to normal activity.
Ensure all flow control activities comply with safety regulations and company policies, promoting a culture of safety and quality first.

Secondary Functions

Assist in physical inventory counts and cycle count programs to ensure system data accuracy.
Participate in continuous improvement projects and Kaizen events aimed at optimizing workflow, reducing lead times, and eliminating waste.
Contribute to the development and maintenance of Standard Operating Procedures (SOPs) for flow control and material handling processes.
Support the training of new team members on system usage, workflow logic, and operational procedures within the facility.

Required Skills & Competencies

Hard Skills (Technical)

High proficiency in Enterprise Resource Planning (ERP) systems, with direct experience in modules like SAP (MM/PP), Oracle, or Microsoft Dynamics 365.
Advanced skills in Microsoft Excel, including pivot tables, VLOOKUPs, conditional formatting, and data analysis functions.
Hands-on experience with Warehouse Management Systems (WMS) for tracking inventory and directing warehouse tasks.
Strong understanding of Lean Manufacturing, Six Sigma, and Just-in-Time (JIT) principles.
Ability to read and interpret production schedules, bills of material (BOMs), and engineering drawings.
Experience with data visualization and KPI reporting tools (e.g., Tableau, Power BI) is a plus.

Soft Skills

Exceptional problem-solving and critical-thinking abilities to quickly diagnose and resolve complex operational issues.
Strong verbal and written communication skills, with the ability to convey critical information clearly and concisely to diverse audiences.
Unwavering attention to detail and a commitment to accuracy in a fast-paced environment.
Excellent organizational and time-management skills, with a proven ability to prioritize and manage multiple competing tasks.
A highly collaborative mindset with strong interpersonal skills to build effective relationships across all levels of the organization.
Resilience, composure, and the ability to make decisive judgments under pressure.

Education & Experience

Educational Background

Minimum Education:

High School Diploma or GED equivalent. An Associate's Degree is often preferred.

Preferred Education:

Bachelor’s Degree.

Relevant Fields of Study:

Supply Chain Management
Logistics
Business Administration
Industrial Engineering

Experience Requirements

Typical Experience Range:

2-5 years of experience in a relevant role within logistics, supply chain, production planning, or a high-volume manufacturing/distribution environment.

Preferred:

Direct experience as a Flow Controller, Expeditor, or Production Controller is highly desirable. Experience in an environment with a complex bill of materials (BOM) and multi-stage production processes is a significant advantage.