Junior APC Engineer

About the Role

Fuller Technologies, with over 140 years of experience in the cement industry, is seeking a Junior APC Engineer to join their Process Optimisation Team. This role focuses on applying advanced process control, analytics, and AI/ML technologies to cement and mining operations worldwide using the ECS/ProcessExpert® APC toolbox and advanced control techniques such as MPC and AI/ML. The goal is to deliver APC and soft-sensor solutions that stabilize plant operations, improve throughput, and reduce energy and fuel consumption. This is a hands-on technical role encompassing the full APC project lifecycle.

Key Responsibilities

• Perform process and data analysis using historical and real-time data to identify optimisation opportunities.
• Design, develop, test, and deploy predictive models and soft sensors using linear and nonlinear 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.
• 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 performance targets.
• 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 project delivery on schedule.
• Provide training and technical mentoring to customer 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 to sales support, product development, feature testing, and service support.

Requirements & Tech Stack

• 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 modern data platforms.
• Familiarity with AI/ML and data analytics tools, including: Python, Pandas, NumPy, Scikit-Learn, TensorFlow, Matplotlib, Seaborn, Databricks.
• Willingness to travel (50–70%) within India and internationally for commissioning, pilot testing, customer engagement, and training.