Senior Controls Engineer

Job Title:

Senior Manufacturing Controls Engineer

Industry Type:

Industrial Machinery Manufacturing / Mechanical or Industrial Engineering

Employment Type:

Full Time Permanent Job Description

Summary Of Job Responsibilities

A Senior Manufacturing Controls Engineer is responsible for designing, implementing, and optimizing manufacturing processes to enhance efficiency, reduce waste, and ensure high-quality production. This position implements corrective actions to resolve manufacturing process problems through testing, evaluation, and analysis.

• Design and develop control systems for manufacturing equipment and processes.
• Identify and implement corrective actions to resolve manufacturing process problems through testing, evaluation, and analysis.
• Implement automation solutions to improve production efficiency and reduce costs.
• Troubleshoot and correct electrical, instrumentation, and process problems associated with production equipment. PLC, HMI, and other control devices, emphasis on PLC controlled servo/stepper motors and sensor technologies.
• Develop and document functional specifications for production systems including the interface between hardware and software.
• Develop factory-wide sustainable standards for automation controls, hardware, software PLC&HMI, and process monitoring.
• Work with cross-functional teams to ensure product designs are optimized for manufacturability and scalability.
• Partner with maintenance, manufacturing engineering, operations, and quality engineering to implement process improvements, i.e. PLC & HMI program changes.
• Partner with maintenance and operations to solve equipment availability (downtime) related to motor driven control elements.
• Create electrical schematics and oversee the build of new industrial electrical control panels, which are NFPA
  79/NEC/UL508A compliant.
• Participate in projects involving equipment upgrades, new installations, and process optimization. SNew Equipment Process (NEP) projects to replace, improve, and/or start manufacturing processes.
• Provide technical guidance, support, and training to the manufacturing team and operations team.
• Actively model values:
  Team, Trust, and Excellence.
• Performs other related duties as assigned.

• Proficiency in PLC programming (e.g., Allen-Bradley, Siemens), SCADA systems, and industrial networking.
• Proficient in Programmable Logic Controllers (PLCs) programming (Rockwell/ Allen Bradley).
• Proficient in HMI program development, to include a wide range of controller generations from SLC
  500 to Control Logix.
• Demonstrated ability to develop Human-Machine Interfaces (HMIs) to facilitate interaction between operators and machinery.
• Knowledge of industry standards and regulations to ensure compliance and maintain safety in control systems.
• Knowledge of servo / stepper motor theory of operations and condition monitoring techniques.
• Demonstrated ability to program and implement a variety of machine sensors (Cognex machine vision, digital, and analog devices).
• Working knowledge of industrial robots and ability to develop repeatable program architecture.
• Knowledge of current standards and codes as related to machine safety and fail-safe design (ISO, NFPA, NEMA, NEC, ANSI).
• Demonstrated ability to connect a variety of plant and machine systems through the required communication protocols (Serial, OPC, FTP).
• Demonstrated experience in Electrical Auto Cad / Solidworks. Must be able to design control circuits, overload protection, create and edit machine electrical drawings.
• Demonstrated experience in data analysis using basic statistical comparison techniques & Statistical Process Control (SPC).
• Experience with Lean Manufacturing, Six Sigma, or similar methodologies is a plus.
• Excellent communication skills, both written and verbal.
• Demonstrated experience working collaboratively with key stakeholders.

• Bachelor’s degree in Electrical Engineering, Controls Engineering, or related field, required.
• 5+ years of experience with controls, automation, electrical design, troubleshooting, and machine commissioning.
• Experience with Rockwell PLCs / HMI, required.
• Systems integration experience, i.e. integration of various servo, sensor and vision technologies through PLC and HMI, required.

To perform the job successfully, an individual should demonstrate the following competencies:

• Safety and Security:
  The individual actively promotes and personally observes all safety procedures. The individual complies with Environmental, Safety, and Hazardous Communications requirements.
• Operational Excellence:
  The individual is dedicated to providing organizational systems for measuring work. The individual seeks to reduce variances in organizational processes.
• Interpersonal
  
  Skills:
  
  The individual remains open to other ideas and exhibits a willingness to try new things.
• Relationships with Others:
  The individual works effectively with others, including superiors and…