The Supervisor – PLC/DCS Technician is responsible for leading a team of PLC/DCS technicians to ensure efficient and compliant operation of all automation systems across production, packaging, and utility equipment. The role combines technical leadership, team management, and cross-functional coordination, ensuring timely troubleshooting, preventive maintenance, and continuous improvement of control systems.
This position is critical for ensuring uptime, audit readiness, and process safety in high-performance manufacturing environments.
Supervise and coordinate daily activities of PLC/DCS technicians for troubleshooting, maintenance, and support tasks.
Ensure timely resolution of automation faults in control systems governing production, packaging, and utility equipment.
Allocate resources for shift coverage, preventive maintenance schedules, and project support.
Review and approve minor control logic changes, ensuring alignment with compliance and change control procedures.
Serve as technical escalation point for complex PLC/DCS faults and interlock-related issues.
Maintain automation documentation, software versioning, and system backups in line with SOPs and audit requirements.
Collaborate with Engineering, Quality, Production, and Validation teams for CAPA, FAT/SAT, and audit preparations.
Mentor junior and mid-level technicians through training, SOP reviews, and hands-on support.
Leadership & Team Oversight
Manage task assignments, performance evaluations, and skills development
Conduct toolbox talks, knowledge sessions, and shift handover reviews
Ensure adherence to safety and quality standards by the team
Technical Escalation & System Reliability
Lead resolution of major automation issues related to:
Siemens, Rockwell, Schneider, or DeltaV systems
SCADA/HMI, network communication, or field device anomalies
Compliance & Documentation Control
Enforce documentation practices for:
Change control, deviation handling, loop diagrams, tag lists, logic backups
Ensure systems meet audit requirements (GAMP 5, 21 CFR Part 11, GDP)
Cross-Functional Coordination
Liaise with:
QA for compliance and validation
Engineering and OEMs for system upgrades or expansions
Production for prioritizing equipment support during critical runs
Preventive & Predictive Maintenance Strategy
Develop and refine PM plans for PLC panels, DCS nodes, and HMI terminals
Monitor system health and generate reports on automation KPIs
Education:
Diploma / B.E. / B.Tech in Instrumentation, Electrical, Electronics, Automation, or Mechatronics
Experience:
10+ years in industrial automation, including at least 3 years in a supervisory or lead technician role
Technical Skills:
In-depth expertise in PLCs (Siemens, Allen-Bradley), DCS (DeltaV, Foxboro), SCADA/HMI
Familiarity with industrial networks (Ethernet/IP, Profibus, Modbus), panel troubleshooting, and I/O systems
Strong understanding of GMP, FDA, ISO 9001, or other regulated frameworks
Leadership Skills:
Ability to lead teams, coordinate across departments, and manage workload priorities
Strong verbal and written communication skills
Proactive mindset toward continuous improvement and risk mitigation