Job Title: Manufacturing Instrumentation Engineer
Job Summary:
The Senior Manufacturing Instrumentation Engineer is responsible for leading the design, implementation, and optimization of complex instrumentation systems and automated manufacturing processes. This role involves overseeing the integration of advanced robotics, conveyors, PLC/SCADA systems, and other automation technologies. The Senior Engineer will take a strategic role in ensuring operational efficiency, leading complex troubleshooting efforts, mentoring junior and mid-level engineers, and collaborating with senior leadership to align automation and instrumentation systems with business objectives. This role requires both deep technical expertise and strong leadership capabilities.
Key Responsibilities:
Leadership and Strategic Planning for Automation Systems:
- Lead the design, development, and implementation of advanced automated systems, including robotics, conveyors, and industrial machinery, ensuring alignment with business goals and operational objectives.
- Define system architecture and specifications for instrumentation systems, ensuring they integrate seamlessly with PLC/SCADA systems for optimal performance.
- Provide strategic direction for the adoption and integration of new automation technologies, focusing on improving efficiency, reducing costs, and enhancing system reliability.
Advanced SCADA and PLC Programming and Optimization:
- Take ownership of programming, configuration, and optimization of PLC and SCADA systems for industrial automation, improving manufacturing processes and ensuring high reliability.
- Lead efforts to troubleshoot, debug, and enhance PLC programs and SCADA configurations, ensuring they meet complex operational requirements and align with production goals.
- Implement best practices and provide guidance on programming techniques, system integration, and automation control.
Project Leadership and Execution:
- Lead large-scale automation projects from conceptualization to successful completion, ensuring that all project milestones are met within scope, budget, and timeline.
- Oversee project teams and coordinate activities between engineering, production, and maintenance departments to ensure the smooth implementation of instrumentation and automation solutions.
- Develop and manage project plans, allocate resources effectively, and mitigate project risks, ensuring successful outcomes.
Operational Excellence and Continuous Improvement:
- Lead initiatives to optimize automated manufacturing systems for greater efficiency, reliability, and throughput, leveraging data analysis and performance monitoring tools.
- Identify bottlenecks and inefficiencies in automation processes, providing solutions to reduce downtime, improve system performance, and enhance production capabilities.
- Implement Lean Manufacturing and Six Sigma methodologies to continuously improve automation systems, reduce waste, and enhance productivity.
Quality Control and Compliance:
- Establish and enforce rigorous quality control protocols for automated systems and instrumentation, ensuring all equipment complies with industry standards, regulatory requirements, and internal specifications.
- Monitor and evaluate the performance of automated systems using quality assurance data, recommending improvements as needed.
- Ensure all instrumentation and control systems meet safety, environmental, and regulatory standards, working closely with quality assurance and compliance teams.
Team Leadership and Mentorship:
- Provide mentorship and technical guidance to junior and mid-level engineers, ensuring their growth and development in automation and instrumentation fields.
- Foster a collaborative environment where engineers are encouraged to share knowledge, contribute to continuous improvement, and innovate.
- Conduct performance reviews, provide feedback, and identify opportunities for professional development for the engineering team.
Troubleshooting and Problem Resolution:
- Lead troubleshooting efforts for complex instrumentation, PLC/SCADA, and automation system issues, ensuring rapid resolution and minimizing production downtime.
- Implement proactive measures to prevent system failures, conducting root cause analysis and taking corrective actions to improve system reliability and performance.
- Manage complex technical issues by collaborating with cross-functional teams, suppliers, and external partners as needed.
Collaboration with Senior Leadership and Stakeholders:
- Work closely with senior management to ensure that automation systems align with broader organizational goals, providing insights on automation projects, performance metrics, and operational improvements.
- Serve as the primary technical liaison for senior leadership and external stakeholders, effectively communicating project progress, risks, and strategic opportunities.
- Contribute to the overall business strategy by providing recommendations on the future direction of manufacturing automation technologies and instrumentation systems.
Documentation and Reporting:
- Ensure all project and system documentation is complete, up-to-date, and compliant with company policies, regulatory requirements, and industry standards.
- Prepare detailed technical reports, project updates, and performance evaluations for senior management and other key stakeholders.
- Oversee the creation of standard operating procedures (SOPs), system specifications, and maintenance schedules for automated systems.
Innovation and Technology Adoption:
- Lead the exploration and adoption of new technologies and tools that could improve automation capabilities, system performance, or cost-efficiency.
- Stay up-to-date with the latest trends in automation, instrumentation, robotics, and industrial control systems, bringing innovative solutions to the company.
Key Focus Areas:
- Strategic Automation Leadership: Lead the design and implementation of advanced automation systems and ensure alignment with business objectives.
- Advanced Programming and Optimization: Provide expertise in PLC/SCADA programming and drive system optimization to meet complex operational needs.
- Project and Team Leadership: Manage large-scale automation projects and mentor engineering teams for continued growth and success.
- Operational Excellence: Drive continuous improvement initiatives to enhance system performance, efficiency, and product quality.
- Collaboration with Leadership: Work closely with senior management to ensure automation systems are integrated with business goals and provide ongoing technical guidance.
Skills and Knowledge Required:
- Expert-level knowledge of PLC and SCADA systems, instrumentation, and industrial automation technologies (e.g., Siemens, Allen-Bradley, Rockwell Automation, ABB, KUKA).
- Strong background in project management, including resource allocation, budgeting, timeline management, and risk mitigation.
- Deep understanding of system integration, process optimization, and quality control in automated manufacturing environments.
- Expertise in troubleshooting complex automation systems, identifying root causes, and implementing solutions to improve system reliability and performance.
- Leadership and mentorship abilities, with experience managing teams and fostering collaboration.
- In-depth knowledge of Lean Manufacturing, Six Sigma, and other operational excellence methodologies.
- Excellent communication and presentation skills, with the ability to engage senior leadership and external partners on technical matters.
Educational Qualifications:
- Bachelor’s or Master’s degree in Instrumentation Engineering, Automation Engineering, Electrical Engineering, Mechanical Engineering, or a related technical field.
- Advanced certifications in PLC programming, SCADA systems, robotics, or industrial automation (e.g., PMP, Lean, Six Sigma) are highly desirable.
Experience:
- 7+ years of experience in industrial automation, instrumentation, or related fields, with at least 3-5 years in a leadership or senior engineering role.
- Proven track record of managing and delivering complex automation projects within the manufacturing sector.
- Significant experience in programming, troubleshooting, and optimizing PLC/SCADA systems and automation equipment.
- Experience mentoring and leading technical teams, as well as collaborating with cross-functional departments.
Tools and Technologies:
- Advanced proficiency with SCADA systems and PLC programming platforms (e.g., Siemens TIA Portal, Rockwell Studio 5000, Wonderware).
- Expertise in industrial robotics (e.g., FANUC, ABB, KUKA) and automation tools.
- Familiarity with data analysis tools for system optimization and performance monitoring.
- Knowledge of diagnostic tools and software used for troubleshooting complex instrumentation and automation systems.
Other Requirements:
- Strong leadership capabilities and the ability to manage teams and projects effectively.
- Ability to make high-level technical decisions that align with business needs and improve manufacturing processes.
- Excellent problem-solving, critical thinking, and decision-making skills.
- Willingness to travel as necessary for project implementation, troubleshooting, and site visits.