The Senior PLC/DCS Technician plays a lead technical role in maintaining, diagnosing, and optimizing automation control systems that operate critical process and packaging equipment. This position demands expert-level understanding of PLC/DCS platforms, field instrumentation, system interfaces, and compliance within GMP or regulated environments.
The senior technician also mentors junior staff, leads troubleshooting escalations, supports audits, and works closely with engineering, QA, and validation teams to ensure seamless equipment operation and data integrity.
Lead the troubleshooting of complex automation faults in PLC/DCS-controlled systems (including safety interlocks, alarms, and PID loops).
Conduct root cause analysis of recurring automation issues and recommend permanent fixes or logic improvements.
Implement minor to moderate logic modifications in PLC/DCS programs (ladder, FBD, SFC) following change control procedures.
Support commissioning and validation teams during loop checks, I/O verification, and equipment qualification.
Maintain backups, manage firmware/software versions, and ensure robust documentation of all control changes.
Interface with HMI/SCADA developers to refine operator interactions, alarms, and data reporting.
Lead and mentor junior technicians in troubleshooting techniques and system understanding.
Participate in internal/external audits and provide compliance-ready records of automation systems.
Advanced PLC/DCS Troubleshooting
Independently resolve hardware/software faults in:
Siemens (TIA Portal, S7), Allen-Bradley (Studio 5000), Schneider, DeltaV, etc.
SCADA/HMI (WinCC, FactoryTalk, iFix, Aveva/Wonderware)
Equipment Automation Support
Lead automation support for:
Mixers, reactors, filling lines, packaging units, CIP/SIP systems, utilities
Interface with field instruments and MCCs for seamless operation
Control Logic & Change Management
Execute controlled changes to PLC/DCS logic under GMP/ISO frameworks
Lead CCR (Change Control Requests), support FAT/SAT reviews
Mentorship & Team Leadership
Train and guide junior technicians on control systems and troubleshooting best practices
Provide feedback to engineering and maintenance leadership on skill gaps and training needs
Compliance & Documentation
Maintain audit-ready documentation:
Loop drawings, I/O maps, tag lists, interlock matrices
Change control logs, backups, deviation records
Ensure compliance with GAMP 5, 21 CFR Part 11, and site SOPs
Education:
Diploma / B.E. / B.Tech in Instrumentation, Electrical, Electronics, Mechatronics, or Automation
Experience:
7–10+ years in automation/control systems within regulated industries or continuous/batch manufacturing
Technical Proficiency:
Deep understanding of PLC/DCS architecture, diagnostics, firmware management
Skilled in interpreting complex P&IDs, control logic diagrams, and panel wiring
Familiarity with data historians, industrial networks (Profibus, Ethernet/IP, Modbus)
Soft Skills:
Excellent troubleshooting and analytical skills
Strong documentation discipline and audit readiness
Proactive mindset with ability to lead under pressure