Director of Project Controls, Pharma, New Manufacturing and R&D Facility

Director of Project Controls, Pharma, New Manufacturing and R&D Facility

Director of Project Controls, Pharma, New Manufacturing and R&D Facility

Business Problem, Context & Initiative Description

Our F500 Global Pharma client is seeking a Director of Project Controls to lead the project controls function for our client’s $4.5B next-generation pharmaceutical manufacturing and R&D site. This role is pivotal in delivering complex capital projects on time, on budget, and in full compliance with our client’s operational and quality standards.

This critical Director will lead all aspects of scheduling, planning, cost control, risk management, and progress reporting across multiple high-stakes, concurrent workstreams, supporting the development and commissioning of this state-of-the-art facility. The facility is expected to be operational in late 2027.

Duties / Expectations of this Role

• Scheduling & Planning
• Develop, manage, and optimize master integrated schedules for all phases: design, procurement, construction, commissioning, and validation.
• Interface with design firms, contractors, and internal teams to maintain realistic and accurate timelines.
• Lead schedule risk analysis and scenario planning using tools like Primavera P6 or equivalent.
• Cost & Budget Controls
• Work with finance and procurement to track capital expenditures, manage cash flow forecasts, and ensure adherence to budget.
• Monitor contractor billing, change orders, and forecasts to complete (ETC/EAC).
• Progress & Performance Monitoring
• Implement KPIs, dashboards, and earned value metrics to provide transparency to stakeholders and executive leadership.
• Produce regular progress reports and presentations for senior leadership and external partners.
• Lead the identification and mitigation of project risks related to time, cost, and resources.
• Own the change management process for scope, cost, and schedule impacts.
• Stakeholder Communication
• Act as a key liaison between engineering, procurement, construction, validation, and operations teams.
• Present schedule and progress insights to senior executives and external stakeholders (e.g., regulators, board).

Must Haves – (Required Experience)

• 10+ years of experience in project controls for large-scale capital projects (ideally $1B+).
• Proven leadership of project controls teams on pharmaceutical, biotech, or complex manufacturing projects.
• Expert in scheduling software: Primavera P6, MS Project, or equivalent.
• Strong working knowledge of cost engineering, earned value, risk analysis, and project delivery methods (EPC, CM, Design-Build).
• Bachelor’s or Master’s in Engineering, Construction Management, or related field.

Nice-to-Haves (Preferred Experience)

• PMP or CCP certification (PMI, AACE).
• Experience with FDA-regulated environments or GMP facilities.
• Familiarity with LEAN construction or Integrated Project Delivery (IPD) methods.
• Strong leadership, presentation, and executive reporting skills.

Travel & Location

Onsite at client’s facility in Lebanon, IN 4 days per week.

Start & Term

Immediate start. Minimum 12-month initial term with high likelihood to extend until the end of 2028 at the completion of the project.

Consulting Rate

Competitive