Key Responsibilities and Required Skills for Flow Controller Assistant

🎯 Role Definition

Are you a master of coordination with a keen eye for detail? This role requires a proactive and highly organized Flow Controller Assistant to become a vital part of our dynamic operations team. In this role, you will be the central nervous system of our material and production flow, ensuring that every component, product, and piece of information moves seamlessly through our processes. You will support the senior Flow Controller by monitoring schedules, tracking inventory, and resolving bottlenecks in real-time. This is a critical hands-on position for someone who thrives in a fast-paced environment and is passionate about driving operational excellence from the ground up. If you're ready to make a tangible impact on our efficiency and success, we want to hear from you.

📈 Career Progression

Typical Career Path

Entry Point From:

Warehouse Associate or Team Lead
Production Operator
Data Entry Clerk (Logistics/Inventory)

Advancement To:

Flow Controller / Production Controller
Supply Chain Analyst
Production Planner / Scheduler

Lateral Moves:

Inventory Analyst
Logistics Coordinator
Junior Buyer / Purchasing Assistant

Core Responsibilities

Primary Functions

Actively monitor and manage the end-to-end flow of materials, components, and finished goods from the receiving dock through production to final shipment.
Utilize Enterprise Resource Planning (ERP) and Material Requirements Planning (MRP) systems (e.g., SAP, Oracle) to track production orders, inventory levels, and material movements in real-time.
Proactively identify and resolve potential bottlenecks in the production or logistics pipeline to prevent costly delays and maintain operational efficiency.
Generate, analyze, and distribute daily and weekly reports on production status, schedule attainment, and inventory accuracy to provide actionable insights to management.
Serve as the primary liaison and communication hub between the production floor, warehouse teams, quality control, and shipping to ensure fully synchronized operations.
Assist in the development, maintenance, and communication of detailed production schedules, ensuring they align with customer demand and material availability.
Coordinate the expediting of critical parts and materials by working closely with the purchasing department and external suppliers to mitigate potential shortages.
Manage and update master data within the ERP system, including bills of materials (BOMs), production routings, and inventory parameters to ensure system accuracy.
Conduct regular physical inventory and cycle counts, investigating and reconciling any discrepancies between physical stock and system records to maintain inventory integrity.
Prepare, issue, and manage work orders and pick lists for the production and warehouse teams, ensuring all necessary information is accurate, clear, and timely.
Monitor and report on key performance indicators (KPIs) such as On-Time Delivery (OTD), inventory turnover, and schedule adherence to track performance against targets.
Actively participate in continuous improvement initiatives, applying lean manufacturing principles (like 5S, Kanban, and VSM) to optimize workflow and eliminate waste.
Investigate and document the root cause of any disruptions in material flow, such as part shortages, quality holds, or equipment downtime, and recommend corrective actions.
Communicate any schedule changes, material risks, or potential disruptions to all relevant internal stakeholders in a clear and timely manner.
Support the management of non-conforming materials by coordinating their quarantine, return to supplier, or disposition as per quality control guidelines.
Ensure all material handling and flow processes are executed in strict compliance with company safety standards and standard operating procedures (SOPs).
Assist in planning and coordinating inbound and outbound logistics, ensuring transportation and carrier pickups are scheduled efficiently to meet deadlines.
Maintain meticulous documentation and digital records for all flow control activities, ensuring a clear and accessible audit trail for compliance and future analysis.
Collaborate with engineering and project management teams on new product introductions (NPI) to help establish an efficient and stable material flow for new components.
Support the senior Flow Controller in strategic capacity and resource allocation planning sessions by providing data-driven insights on current operational performance.

Secondary Functions

Support ad-hoc data requests and exploratory data analysis to answer specific business questions from leadership.
Contribute to the organization's data strategy and roadmap by identifying opportunities for improved data collection and process tracking.
Collaborate with business units to translate data needs into engineering requirements for system enhancements.
Participate in sprint planning and agile ceremonies within the operations and data teams to align on priorities and deliverables.

Required Skills & Competencies

Hard Skills (Technical)

High proficiency in Enterprise Resource Planning (ERP) systems, with direct experience in modules like SAP S/4HANA, Oracle NetSuite, or Microsoft Dynamics 365.
Advanced skills in Microsoft Excel, including the ability to create complex formulas, pivot tables, VLOOKUPs, and charts for data analysis and reporting.
Experience with Manufacturing Execution Systems (MES) for real-time monitoring and control of the production floor.
A strong, practical understanding of inventory management principles, including Just-In-Time (JIT), cycle counting, safety stock calculation, and ABC analysis.
Foundational knowledge of production planning and scheduling concepts and their impact on material flow.
Familiarity with lean manufacturing and continuous improvement methodologies such as Kanban, 5S, and Value Stream Mapping (VSM).
The ability to read, interpret, and work with technical documents like production schedules, Bills of Materials (BOMs), and engineering drawings.
Strong data analysis and reporting skills, with the ability to transform raw data into clear, actionable insights and KPI dashboards.
Basic understanding of logistics principles and Warehouse Management Systems (WMS).
Experience with data visualization tools like Tableau or Power BI is a significant advantage.

Soft Skills

Exceptional attention to detail and a commitment to accuracy in all tasks.
Strong analytical and problem-solving skills with the ability to think on your feet.
Excellent verbal and written communication skills, capable of liaising effectively between different departments.
High level of personal organization and the ability to manage multiple priorities in a fast-paced environment.
A proactive, self-starting attitude with a strong sense of urgency and ownership.
Proven ability to collaborate effectively as part of a team to achieve common goals.
Resilience and composure when working under pressure and facing unexpected challenges.
A continuous improvement mindset, always looking for ways to make processes better.

Education & Experience

Educational Background

Minimum Education:

High School Diploma or GED required.

Preferred Education:

Associate's or Bachelor's Degree.

Relevant Fields of Study:

Supply Chain Management
Logistics
Business Administration
Operations Management

Experience Requirements

Typical Experience Range: 1-3 years of relevant experience in a related role.

Preferred:

Prior experience in a high-volume manufacturing, distribution, or e-commerce fulfillment environment is highly desirable.
Demonstrable experience working directly with an ERP/MRP system on a daily basis.