Job Title: Factory Systems Engineer
Job Summary:
The Factory Systems Engineer Manager is responsible for leading the overall strategy, implementation, optimization, and maintenance of factory systems and automation technologies within a manufacturing environment. This includes overseeing control systems such as PLCs, SCADA, MES, HMI, and robotics, ensuring seamless integration, high performance, and alignment with production objectives. The Manager will lead a team of engineers, collaborate with cross-functional departments, and drive process improvements and innovation to optimize manufacturing operations. This role also involves managing system upgrades, ensuring compliance with quality and safety standards, and overseeing large-scale automation projects.
Key Responsibilities:
Leadership and Team Management:
- Lead, manage, and mentor a team of Factory Systems Engineers and technicians, providing technical guidance and fostering a collaborative, high-performance work environment.
- Set team goals and objectives, conduct performance reviews, and support career development for team members.
- Delegate tasks effectively, prioritize team activities, and ensure that operational objectives are met in a timely and efficient manner.
Factory Systems Strategy and Optimization:
- Develop and execute a comprehensive strategy for factory automation and control systems to meet production and business goals.
- Oversee the design, integration, and optimization of PLC-based systems, SCADA, MES, robotics, and other automation technologies to improve factory productivity, minimize downtime, and enhance operational efficiency.
- Continuously monitor system performance and drive improvements based on data analysis and operational feedback.
Project Leadership and Execution:
- Lead and manage large-scale factory systems projects, including system installations, upgrades, and integrations.
- Oversee the planning, execution, and completion of projects, ensuring that they are delivered on time, within budget, and meet technical specifications.
- Manage resources, timelines, budgets, and risks associated with factory automation projects and ensure minimal disruption to ongoing operations during implementation.
Process Improvement and Innovation:
- Identify opportunities for process improvement through automation, system upgrades, and integration of new technologies.
- Lead continuous improvement initiatives using methodologies like Lean Manufacturing, Six Sigma, and root cause analysis to reduce waste, optimize processes, and improve system performance.
- Introduce innovative solutions and technologies that enhance factory productivity, increase product quality, and reduce operational costs.
Collaboration with Cross-Functional Teams:
- Collaborate closely with production, maintenance, quality, IT, and engineering teams to ensure factory systems meet production needs and quality standards.
- Act as the technical liaison between factory systems engineering and other departments, ensuring that systems are aligned with operational goals and production requirements.
- Provide expert advice on automation and process control systems during strategic planning, budget discussions, and capital investment projects.
Safety and Compliance:
- Ensure that factory systems comply with industry safety standards, regulatory requirements, and company policies.
- Work with safety, quality, and regulatory teams to implement safety protocols for factory systems and ensure compliance with environmental and safety regulations.
- Lead safety audits and ensure that all factory systems operate in a safe and controlled environment.
Maintenance and Troubleshooting Oversight:
- Oversee the maintenance and troubleshooting of factory systems, ensuring that all control systems and automation technologies are properly maintained and perform optimally.
- Ensure that routine and preventive maintenance activities are performed on automation systems to minimize equipment downtime.
- Direct troubleshooting efforts for complex system failures and provide guidance on corrective actions to restore production.
Documentation and Reporting:
- Ensure accurate and up-to-date documentation for all factory systems, including system configurations, changes, maintenance logs, and troubleshooting records.
- Prepare regular reports for senior management, detailing system performance, key metrics, issues, and improvement initiatives.
- Develop and maintain comprehensive documentation of processes, systems, and safety protocols for reference and compliance purposes.
Budget and Resource Management:
- Oversee the budget for factory systems engineering, ensuring that resources are allocated efficiently and cost-effectively.
- Manage procurement of necessary equipment, software, and tools for the factory systems team.
- Ensure that expenditures align with project budgets and cost-saving initiatives are identified and implemented.
Key Focus Areas:
- Factory Systems Strategy and Optimization: Lead the design and optimization of factory automation systems to achieve production goals and operational efficiency.
- Project Management: Manage large-scale projects, including system integration, upgrades, and new installations, ensuring timely and within-budget execution.
- Continuous Improvement and Innovation: Drive process improvements through the integration of new technologies, automation, and continuous improvement methodologies.
- Team Leadership and Development: Lead and develop a team of engineers, fostering a culture of continuous learning and performance excellence.
- Collaboration and Communication: Ensure seamless collaboration with cross-functional teams and senior management to meet production and business objectives.
Skills and Knowledge Required:
- Extensive experience with factory automation systems, PLCs, SCADA, MES, HMI, robotics, and industrial control systems.
- Strong project management skills, with experience managing large-scale automation and system integration projects.
- Proven ability to lead and mentor a team of engineers, promoting teamwork and continuous learning.
- Strong analytical and problem-solving skills, with the ability to identify process inefficiencies and implement solutions.
- Knowledge of Lean Manufacturing, Six Sigma, or other process improvement methodologies.
- In-depth knowledge of safety standards, regulatory compliance, and quality control in manufacturing systems.
- Excellent communication skills, with the ability to collaborate across departments and present technical solutions to senior leadership.
Educational Qualifications:
- Bachelor’s or Master’s degree in Electrical Engineering, Automation Engineering, Mechatronics, Industrial Engineering, or a related technical field.
- Certifications in PLC programming, industrial automation, project management (e.g., PMP), or process optimization (e.g., Six Sigma, Lean) are highly desirable.
Experience:
- 7+ years of experience in industrial automation, PLC-controlled systems, and process control systems, with at least 3-5 years in a leadership or managerial role.
- Proven experience leading large-scale factory automation projects, including system integrations and upgrades.
- Experience managing teams, overseeing system optimizations, and driving process improvement initiatives.
Tools and Technologies:
- Expertise in PLC programming platforms (e.g., Siemens TIA Portal, Rockwell Studio 5000, Mitsubishi GX Works).
- Experience with SCADA, HMI, MES systems, and industrial automation software.
- Strong knowledge of diagnostic tools and performance monitoring systems for factory systems.
- Familiarity with industrial control components such as sensors, actuators, robotics, and drives.
Other Requirements:
- Strong leadership and decision-making capabilities to manage both technical and operational challenges.
- Ability to handle multiple projects and priorities in a fast-paced, dynamic manufacturing environment.
- Willingness to travel occasionally for site support, system installations, training, or troubleshooting.