Job Title: Factory Systems Engineer

Job Summary:

The Mid-Level Factory Systems Engineer is responsible for managing, optimizing, and maintaining the automation systems used in a manufacturing environment. This role involves overseeing the integration, troubleshooting, and performance enhancement of control systems (PLCs, SCADA, HMI, MES), robotics, and industrial equipment. The Factory Systems Engineer will work closely with production, maintenance, and engineering teams to ensure that factory systems operate efficiently, meet production goals, and adhere to quality standards. Additionally, the engineer will lead improvement initiatives, mentor junior engineers, and assist with the implementation of new technologies.

Key Responsibilities:

1. Factory Systems Maintenance and Optimization:

   • Oversee the setup, configuration, and routine maintenance of process control and automation systems, including PLCs, SCADA, HMI, MES, and industrial robotics.
   • Optimize the performance of factory systems to improve production efficiency, reduce downtime, and ensure reliable system performance.
   • Lead troubleshooting efforts for complex issues related to control systems, instrumentation, and automation equipment to prevent or minimize disruptions.

2. System Integration and Upgrades:

   • Lead the integration of new systems or technologies into the existing factory automation infrastructure, ensuring seamless operation across equipment and platforms.
   • Collaborate with engineering teams to design and implement system upgrades or modifications to support production requirements and incorporate new technologies.
   • Manage and oversee the commissioning of new automation systems and ensure proper configuration, testing, and integration into the production environment.

3. Monitoring and Data Analysis:

   • Monitor the performance of automated systems in real-time, tracking key performance indicators (KPIs) and providing analysis of system efficiency.
   • Collect and analyze data from factory systems to identify opportunities for improvement, such as reducing waste, improving throughput, or increasing reliability.
   • Prepare reports and performance metrics for senior management, highlighting system performance, ongoing improvements, and areas requiring attention.

4. Collaboration with Cross-Functional Teams:

   • Work closely with production, maintenance, quality assurance, and engineering teams to ensure factory systems meet production goals and comply with quality standards.
   • Provide technical support and training to operators and maintenance personnel on how to effectively use factory systems and troubleshoot minor issues.
   • Communicate and coordinate with senior leadership to ensure automation systems align with business objectives and production requirements.

5. Process Improvement and Continuous Optimization:

   • Lead continuous improvement initiatives to enhance manufacturing operations, including process control and automation optimizations.
   • Utilize Lean Manufacturing, Six Sigma, and other methodologies to identify process inefficiencies and implement solutions that improve operational performance.
   • Develop and implement strategies to minimize downtime, improve system reliability, and ensure consistent product quality.

6. Training and Mentorship:

   • Mentor junior engineers and technicians, providing guidance on system configuration, troubleshooting, and process optimization.
   • Assist in the development of training materials and programs to improve team knowledge of factory automation systems and best practices.
   • Help create a culture of knowledge sharing within the team to ensure continuous skill development.

7. Documentation and Compliance:

   • Ensure all system configurations, calibration records, maintenance logs, and troubleshooting actions are accurately documented.
   • Maintain documentation in compliance with safety standards, quality requirements, and industry regulations.
   • Prepare technical reports for senior management and provide insights into ongoing system improvements, performance metrics, and any issues encountered.

8. Safety and Quality Assurance:

   • Ensure factory automation systems and control equipment adhere to safety standards and regulatory compliance requirements.
   • Collaborate with the safety and quality teams to implement safety protocols, equipment standards, and quality control procedures for automated systems.
   • Conduct periodic safety audits and ensure compliance with safety regulations.

Key Focus Areas:

• System Optimization and Troubleshooting: Manage the performance of PLC-controlled systems, SCADA, MES, and other automation technologies to ensure optimal production output and system reliability.
• System Integration and Upgrades: Lead the integration of new systems and upgrades to improve manufacturing processes and ensure system compatibility.
• Collaboration and Leadership: Work with cross-functional teams to enhance factory operations and mentor junior engineers.
• Continuous Improvement: Drive process improvements using Lean Manufacturing, Six Sigma, and data-driven analysis to optimize system performance and production efficiency.

Skills and Knowledge Required:

• Strong knowledge of process control systems, PLC programming, automation technologies, and industrial instrumentation.
• Experience with SCADA, HMI, MES, and other control systems used in manufacturing automation.
• Proficiency in troubleshooting, diagnosing, and resolving issues related to PLCs, robotics, and other control systems.
• Experience with process improvement methodologies such as Lean Manufacturing or Six Sigma.
• Strong data analysis skills, with the ability to use data to identify process inefficiencies and optimize production systems.
• Excellent communication and leadership skills, with the ability to work collaboratively with cross-functional teams and mentor junior engineers.
• Familiarity with industry regulations, safety standards, and quality control procedures related to process control systems.

Educational Qualifications:

• Bachelor’s degree in Electrical Engineering, Automation Engineering, Mechatronics, Industrial Engineering, or a related technical field.
• Certifications in PLC programming, industrial automation, or process optimization (e.g., Six Sigma, Lean) are highly desirable.

Experience:

• 3-5 years of experience working with factory automation, PLC-controlled systems, and process control in manufacturing environments.
• Proven experience in troubleshooting, optimizing, and maintaining automation systems in a production setting.
• Experience with SCADA, HMI, MES systems, and other industrial control platforms is a plus.
• Experience in leading process improvement initiatives, with knowledge of Lean Manufacturing or Six Sigma principles.

Tools and Technologies:

• Proficiency with PLC programming software (e.g., Siemens, Rockwell Studio 5000, Mitsubishi GX Works).
• Experience with SCADA, HMI, and MES systems (e.g., Wonderware, Ignition, Siemens).
• Familiarity with industrial control components such as sensors, actuators, robotics, and drives.
• Strong familiarity with data analysis tools and performance monitoring systems.

Other Requirements:

• Strong leadership and project management skills to oversee the optimization and integration of automation systems.
• Ability to manage multiple projects, tasks, and priorities effectively.
• Willingness to travel occasionally for system installations, training, or troubleshooting.