Job Summary

Senior APC Engineer - Process Optimisation Applications (PXP) As a Senior APC Engineer, you will carry this legacy forward by applying advanced process control, analytics, and AI/ML technologies to cement and mining operations worldwide. At Fuller, APC engineering is not just about control algorithms - it is about understanding the process, earning customer trust, and delivering performance that lasts.

You will be part of Fullers Process Optimisation Team, working with the ECS/ProcessExpert APC toolbox and advanced control techniques such as MPC and AI/ML. Your role focuses on delivering APC and soft-sensor solutions that stabilise plant operations, improve throughput, and reduce energy and fuel consumption.

This is a hands-on technical role with responsibility across the full APC project lifecycle - from process analysis and model development to commissioning, optimisation, and long-term performance support.

Responsibilities

- Perform process and data analysis using historical and real-time data from cement and minerals plants to identify optimisation opportunities.
- Design, develop, test, and deploy predictive models and soft sensors using linear and non-linear AI/ML algorithms.
- Implement, validate, and maintain real-time APC applications using MPC, AI/ML, fuzzy logic, and PID control strategies.
- Estimate and quantify process improvement benefits using data analytics, supporting performance guarantees and technical proposals.
- Adapt, tune, and retrain models and controllers to ensure sustained performance and operational stability.
- Define and implement process control strategies, including configuration and commissioning of APC solutions.
- Fine-tune MPC, fuzzy, and PID controllers to achieve guaranteed performance targets related to productivity, energy efficiency, and stability.




- Support system integration activities, including hardware selection, software installation, and connectivity with PLCs, DCS, and historians.
- Collaborate with project managers and customer teams to ensure APC projects are delivered on schedule and to specification.
- Provide training and technical mentoring to APC engineers on data analytics and AI/ML applications within the ECS/ProcessExpert platform.
- Evaluate emerging developments in advanced analytics and non-linear modelling to continuously improve APC applications.
- Contribute across the broader APC lifecycle, including sales support, product development, feature testing, and service support as required.

Qualifications

- Strong hands-on experience in Advanced Process Control, Data Analytics, Machine Learning, and AI applied to industrial processes.
- Proven experience in data mining, statistical modelling, model deployment, and real-time implementation.
- Background in process manufacturing industries; cement and minerals process knowledge is a strong advantage.
- Solid understanding of process optimisation, control strategy development, and benefit analysis.
- Experience with industrial data connectivity and historians, including SQL, MQTT, PLCs, DCS, and contemporary data platforms.
- Familiarity with AI/ML and data analytics tools commonly used in process industries, including: Python, Pandas, NumPy, Scikit-Learn, TensorFlow, Matplotlib, Seaborn, Databricks
- Willingness to travel (40-60%) within India and internationally for commissioning, pilot testing, customer engagement, and training.

Disclaimer: This job posting has been aggregated from external source. Role details, content, and availability are subject to change. Applicants are advised to confirm the latest information directly on the company website before applying.

📌 Senior APC Engineer - Process Optimisation Applications (PXP) (Chennai)
🏢 FLSmidth Cement
📍 Chennai