Job Title: Factory Systems Engineer
Job Summary:
The Senior Factory Systems Engineer is responsible for leading and managing the optimization, integration, and maintenance of factory automation and control systems, including PLCs, SCADA, HMI, MES, and robotics. This role involves ensuring that manufacturing systems operate efficiently, cost-effectively, and meet production goals. The Senior Factory Systems Engineer will lead complex projects, mentor junior engineers, collaborate with cross-functional teams, and continuously drive system improvements. This position requires deep technical expertise in automation, strong leadership capabilities, and the ability to drive process optimization initiatives across the factory.
Key Responsibilities:
Leadership and System Optimization:
- Lead the optimization, integration, and troubleshooting of factory automation systems, including PLCs, SCADA, HMI, MES, and robotics, to improve overall system performance.
- Take ownership of complex control system configurations, upgrades, and improvements to meet manufacturing demands, improve uptime, and reduce operational costs.
- Lead efforts to identify and implement process control system improvements that enhance production efficiency, reduce downtime, and improve quality.
Project Leadership and Execution:
- Oversee large-scale system integration and automation projects from planning to execution, ensuring projects are delivered on time, within budget, and meet all technical specifications.
- Coordinate with cross-functional teams, including production, maintenance, engineering, and IT, to ensure that system requirements align with operational needs.
- Manage resources, timelines, and budgets for system upgrades, ensuring minimal disruption to ongoing operations during project implementation.
System Design and Integration:
- Design and implement system architecture for integrating new automation technologies, equipment, and control systems into existing factory environments.
- Lead the integration of new technologies or process improvements into the production systems, ensuring they are compatible and enhance overall productivity.
- Oversee the commissioning, testing, and calibration of new systems to ensure successful system integration and compliance with operational requirements.
Troubleshooting and Advanced Support:
- Lead troubleshooting and diagnostics for complex technical issues related to PLC-controlled systems, automation equipment, and control devices.
- Provide guidance and support to production teams during system failures or production disruptions, ensuring rapid issue resolution and system recovery.
- Conduct root cause analysis on recurring issues and implement long-term solutions to prevent future disruptions.
Continuous Improvement and Process Optimization:
- Drive continuous improvement initiatives to enhance factory system performance, utilizing Lean Manufacturing, Six Sigma, and other process optimization methodologies.
- Identify process inefficiencies, system bottlenecks, and opportunities for automation to increase production throughput and product quality.
- Implement data-driven improvements by analyzing performance metrics, downtime reports, and feedback from operators and engineers.
Mentorship and Team Development:
- Mentor and provide technical guidance to junior engineers and technicians, fostering a culture of continuous learning and professional growth.
- Lead training programs for engineers and operators on new systems, process control technologies, and troubleshooting techniques.
- Conduct performance reviews and provide constructive feedback to ensure the team is aligned with production goals and operational excellence.
Documentation and Compliance:
- Ensure that all factory system designs, configurations, modifications, and troubleshooting activities are thoroughly documented and comply with company standards, safety protocols, and regulatory requirements.
- Prepare detailed technical reports for senior management, highlighting system performance, improvement initiatives, and challenges.
- Ensure compliance with industry standards and certifications related to process control, automation, and quality assurance.
Collaboration with Senior Leadership:
- Collaborate with senior management to define system strategies, align goals, and optimize the use of automation technologies in meeting production and business objectives.
- Provide technical expertise to leadership teams on the capabilities of current systems and opportunities for improvements and innovations.
- Contribute to long-term business strategies by recommending new technologies or process control systems that can improve operational efficiency and reduce costs.
Safety and Quality Assurance:
- Ensure all factory systems comply with industry safety standards, environmental regulations, and quality assurance protocols.
- Collaborate with safety and quality teams to ensure that control systems are safe, reliable, and produce consistent, high-quality products.
- Develop and implement safety and maintenance protocols for system operations, addressing potential hazards and ensuring compliance with safety regulations.
Key Focus Areas:
- System Optimization and Troubleshooting: Lead the optimization, troubleshooting, and improvement of factory automation systems, ensuring efficiency and minimizing downtime.
- Project and Resource Management: Oversee large-scale system upgrades, integrations, and improvements, managing resources, timelines, and budgets.
- Continuous Improvement: Drive continuous improvement projects using Lean, Six Sigma, and data analysis to enhance factory system performance.
- Leadership and Mentorship: Lead and mentor a team of engineers and technicians, fostering a culture of continuous learning and performance excellence.
- Safety and Compliance: Ensure all factory systems meet safety, regulatory, and quality control standards.
Skills and Knowledge Required:
- Expertise in PLC programming, SCADA, MES, HMI, and industrial automation systems used in manufacturing environments.
- Extensive experience in troubleshooting, maintaining, and optimizing process control systems and automated production lines.
- In-depth knowledge of process control, instrumentation, and automation technologies used in industrial settings.
- Strong leadership skills, with the ability to manage teams, oversee projects, and mentor junior engineers.
- Proven ability to implement process improvements using Lean Manufacturing, Six Sigma, or other continuous improvement methodologies.
- Strong analytical skills, with the ability to analyze performance data and identify optimization opportunities.
- Excellent communication and collaboration skills to interact with senior leadership, cross-functional teams, and external vendors.
Educational Qualifications:
- Bachelor’s or Master’s degree in Electrical Engineering, Automation Engineering, Mechatronics, Industrial Engineering, or a related technical field.
- Relevant certifications in PLC programming, industrial automation, project management (e.g., PMP), and process optimization (e.g., Six Sigma, Lean) are highly desirable.
Experience:
- 7+ years of experience in industrial automation, PLC-controlled systems, process control, or related fields, with at least 3-5 years in a senior role.
- Extensive experience with system integrations, troubleshooting, and optimizing automated manufacturing systems.
- Proven leadership experience, with a track record of managing teams, projects, and process optimization initiatives.
Tools and Technologies:
- Expertise with PLC programming platforms (e.g., Siemens TIA Portal, Rockwell Studio 5000, Mitsubishi GX Works).
- Experience with SCADA, MES, and HMI systems (e.g., Wonderware, Ignition, Siemens).
- Familiarity with industrial control components such as sensors, actuators, robotics, and drives.
- Strong knowledge of performance monitoring and diagnostic tools for process control systems.
Other Requirements:
- Strong leadership and project management skills to guide and develop teams and manage large-scale system upgrades.
- Ability to handle multiple projects and priorities in a fast-paced manufacturing environment.
- Willingness to travel occasionally for site support, system installations, or troubleshooting.