Process Automation Engineer

Location: Bridgeton

Job Title:

Process Automation Engineer

Job Description

The Process Automation Engineer plays a key role in optimizing and automating manufacturing processes across the plant. This position focuses on scaling up production for existing product lines, supporting the introduction of new products, and driving continuous improvement through advanced automation, PLC and HMI programming, and capital projects. The role requires a strong electrical and mechanical aptitude, hands-on engagement on the manufacturing floor, and the ability to independently take projects from concept through implementation while collaborating with cross-functional teams and external contractors.

Responsibilities

+ Optimize manufacturing processes throughout the plant with a primary focus on automation and continuous improvement.

+ Work to improve key performance indicators (KPIs) including safety, quality, productivity, cost improvement, overall equipment effectiveness (OEE), and 5S activities.

+ Manage documentation and control of all production line PLC programs and automation software.

+ Perform heavy PLC programming and HMI programming, including programming from scratch when needed.

+ Conduct routine troubleshooting on mechanical and electrical equipment to quickly resolve issues and minimize downtime.

+ Support and document preventive maintenance procedures for production line equipment.

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

+ Update legacy equipment and support the installation and commissioning of new automated systems and production lines.

+ Assist in developing Standard Operating Procedures (SOPs) for equipment inspection, operation, and maintenance.

+ Assist with the design of products and mechanical, electrical, and control systems using tools such as AutoCAD.

+ Develop, design, and implement annual capital plans and strategic projects, ranging from small to multi-million-dollar scopes.

+ Evaluate production capabilities and constraints for new product development (NPD) projects and support the introduction of new products and innovations into manufacturing.

+ Lead and organize Lean Six Sigma activities to support continuous improvement initiatives across the plant.

+ Identify and resolve root causes of recurring downtime and chronic equipment issues.

+ Identify and implement opportunities to increase unit output and overall line capacity.

+ Implement cost savings and process improvement projects to enhance operational efficiency and reduce waste.

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

+ Research and analyze customer design proposals, specifications, manuals, and technical data 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 production and maintenance personnel as needed.

+ Model and support core organizational capabilities to achieve service excellence, meet and exceed operational objectives, and support fiscal responsibility.

+ Promote and maintain a safe, healthy work environment free of intimidation and harassment, and ensure adherence to all company policies and procedures.

+ Demonstrate safe work practices at all times and ensure that safety is integrated into all engineering and project activities.

+ Collaborate closely with cross-functional teams, including product development, maintenance, operations, and external contractors, to deliver successful project outcomes.

+ Operate in a highly autonomous manner by taking high-level objectives, developing practical solutions, and executing projects with minimal oversight.

+ Perform other related duties and special projects as assigned.

Essential Skills

+ Proven experience in process engineering within a manufacturing environment with heavy automation.

+ Strong hands-on experience with process automation and straight-line manufacturing processes.

+ Advanced PLC programming skills, including the ability to program from scratch using ladder logic.

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Experience with Allen-Bradley PLCs and related automation platforms.

+ Proficiency in HMI programming for automated production equipment.

+ Solid electrical background with the ability to understand and work with electrical systems and controls.

+ Mechanical aptitude and the ability to understand, evaluate, and improve mechanical systems and equipment.

+ Proficiency with AutoCAD for designing and updating mechanical, electrical, and control system drawings.

+ Experience in troubleshooting both mechanical and electrical issues on production equipment.

+ Demonstrated ability to manage multiple projects simultaneously,…