Process Automation Engineer

Location: Bridgeton

Job Title:

Process Automation Engineer

Job Description

The Process Automation Engineer drives process engineering and automation initiatives across the manufacturing plant, with a strong focus on scaling production, upgrading equipment, and implementing continuous improvement. This role designs, programs, and optimizes automated systems, including PLCs and HMIs, while leading capital projects from concept through installation and startup. The engineer works cross-functionally with internal teams and external contractors, supports new product introductions, and improves safety, quality, and efficiency on highly automated production lines.

Responsibilities

+ Lead process engineering and automation efforts across the plant to optimize existing production lines and support the integration of new lines and products.

+ Develop, program, and modify PLC and HMI systems, including programming from scratch when needed, with a strong emphasis on Allen-Bradley platforms and ladder logic.

+ Manage documentation and control of all production line PLC programs and automation software to ensure accuracy, standardization, and change control.

+ Evaluate manufacturing equipment and processes on the production floor, diagnose issues, identify root causes of downtime, and implement effective technical solutions.

+ Conduct routine troubleshooting of mechanical and electrical equipment to minimize downtime and improve overall equipment effectiveness (OEE).

+ Support and document preventive maintenance procedures and assist in the development of Standard Operating Procedures for equipment inspection and maintenance.

+ Direct and coordinate the fabrication, installation, and commissioning of new equipment and processes to ensure conformance to engineering designs and customer specifications.

+ Design or assist with the design of products and mechanical, electrical, and control systems to support manufacturing and automation requirements.

+ Develop, design, and implement annual capital plans and strategic projects, ranging from small-scale initiatives to multi-million-dollar investments, while managing multiple projects simultaneously.

+ Research alternatives and develop capital requests for new machines and processing lines to increase capacity and efficiency.

+ Collaborate with product development teams to evaluate production capabilities and support New Product Development projects and product innovations.

+ Work to improve key performance indicators (KPIs) focused on safety, quality, productivity, cost improvement, OEE, and 5S activities.

+ Lead and organize Lean Six Sigma and other continuous improvement activities to enhance safety, quality, and efficiency on manufacturing lines.

+ Identify and implement cost savings and process improvement projects to increase unit output and reduce operating costs.

+ Maintain accurate and organized project and equipment files to ensure information is readily available and up to date.

+ Research and analyze data such as customer design proposals, specifications, and technical manuals to determine feasibility of designs or applications.

+ Plan the fabrication of test control apparatus and equipment and develop methods and procedures for testing products or systems.

+ Supervise and support field installations of equipment and recommend design modifications to eliminate machine or system malfunctions.

+ Provide technical training on production line equipment and automation systems to operations and maintenance personnel as needed.

+ Model and promote core capabilities and behaviors that support service excellence, operational effectiveness, and fiscal responsibility.

+ Promote and maintain a safe, healthy, and respectful work environment, demonstrating safe work practices at all times and complying with all company policies and procedures.

+ Act as a highly autonomous project leader who can take a concept or high-level objective, define the approach, and execute through to completion with minimal oversight.

+ Perform other related engineering and project duties as assigned.

Essential Skills

+ Proven experience in process engineering within a manufacturing environment involving heavy automation and straight-line manufacturing processes.

+ Strong hands-on PLC programming experience, including programming from scratch using ladder logic.

+ Proficiency with Allen-Bradley PLCs and related automation hardware and software.

+ Demonstrated experience with HMI programming and interface design for automated systems.

+ Solid electrical background with the ability to troubleshoot and support electrical systems on production equipment.

+ Ability to read, create, and modify AutoCAD designs and drawings for equipment, layouts, and control systems.

+ Strong mechanical aptitude and familiarity with automated machinery such as robotic palletizers, bottle sorters, liquid fillers, and cap applicators or similar equipment.

+ Experience managing multiple capital and process improvement projects simultaneously, from concept through implementation.

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