Manufacturing Controls Engineer

Overview

We are currently seeking a Manufacturing Controls Engineer to join our team in our Poynette manufacturing plant. In this role you will be responsible for project ownership and need to successfully balance time between both projects and delivering quality technical support when needed to keep the day-to-day operation successful. The ideal candidate will also be the expert onsite for troubleshooting industrial systems when problems are elevated through Maintenance and ME techs.

• Design, development and programming of PLC and touchscreen based automated controls, specifically:
  • Development and documentation of needed processes.
  • Selection of appropriate PLC, GUI touchscreen, sensors, user interface, servo mechanism, motor, motor starters, variable frequency drives and enclosure.
  • Develop of control input/output list.
  • Using sound engineering principles, current technology and April Aire documentation standards provide CAD documentation of conceptual control system.
  • Manage fabrication of control system.
  • Development of PLC and/or GUI touch-screen code based on process.
  • Perform first I/O test of PLC and/or GUI touchscreen.
  • Debugging, implementation, and documentation of control system.
  • Development of training documents for Maintenance and Production Staff.
• Manage projects where you and/or outside contractors or internal resources are responsible for the design, fabrication, programming, and implementation of manufacturing equipment, specifically:
  • Conformance of equipment to April Aire standard components and programming specifications.
  • Equipment compliance with OSHA, ANSI, and NEC safety standards.
  • Adherence to project timeline and budget.
  • Appropriateness of equipment operation for production staff and conformance to April Airequality standards.
  • Documentation required to turn equipment over to Production/Plant Maintenance.
• Propose manufacturing equipment projects including identification of projects, development of project cost, timeline, resources, savings, and payback, and preparation and submittal of proposal to Manufacturing Management.
• Serve as the highest-level controls/electrical troubleshooter before vendors are contacted and a resource for Maintenance and Manufacturing Engineering Technicians to problem solve unknowns, support troubleshooting methodology, and train when root cause is found.
• Troubleshoot automated control systems, specifically:
  • Safely troubleshoot 480V 3 phase,230V 3 phase, 240V and 120v, along with controls 24
    
    VDC to root cause failures
  • At times follow through with full remediation of root cause failures without assistance
  • Modify PC, PLC, and touch–screen software as required to support Plant Maintenance and needs of Production Staff.
  • Identify and specify available replacement components for obsolete or unavailable components.
  • Maintain records of modifications to existing automated control systems.
• Work collaboratively with Design Engineers, Product Engineers and other departments as required to maintain product quality and manufacturing efficiency.
• Perform such liaison as may be required to obtain information, services, and materials necessary for projects by telephone, travel to or visits by vendor representatives.
• Diagnose production problems and recommend solutions to these problems.
• Keep abreast of and well informed on new developments in machine design and controls.
• Conduct basic research and development work on mechanical/electrical systems to provide optimum efficiency for manufacturing equipment or processes.
• Represent the Manufacturing Department as a member of product design teams as assigned.
• Practice safety and make safety a primary concern in all projects.

• Bachelor’s degree in manufacturing, mechanical, electrical, or controls engineering, or other closely related discipline, or an equivalent combination of education and experience.
• Two to three years minimum of general manufacturing machine or process design experience required to assure full project accountability from concept through project completion.
• Knowledge of design techniques, tools, and principles involved in the development of automated control systems.
• Knowledge of drafting standards.
• Knowledge of machines and tools, including their designs, uses, repair, and maintenance.
• Knowledge of circuit boards, processors, chips, electronic equipment, and computer hardware and software, including applications and programming.
• Knowledge of selection, programming, implementing, and troubleshooting PLCs and user interface touch screens.