Job Title: PLC Engineer

Job Summary:

The Senior PLC Engineer is responsible for overseeing the design, programming, optimization, and maintenance of complex PLC-based control systems for industrial, commercial, and manufacturing applications. This leadership role requires in-depth technical expertise in PLC programming, system integration, and troubleshooting of automation systems. The Senior PLC Engineer will lead projects, mentor junior and mid-level engineers, and collaborate with cross-functional teams to improve system performance, reduce downtime, and ensure compliance with safety and regulatory standards. This role involves managing complex projects, providing advanced technical support, and driving continuous improvements in automation and control systems.

Key Responsibilities:

1. PLC System Design and Architecture:

   • Lead the design, development, and implementation of large-scale PLC systems for automation, ensuring they meet client specifications, industry standards, and operational requirements.
   • Develop and define control strategies, system architectures, and integration plans for PLCs and other automation components.
   • Oversee the creation and review of detailed system documentation, including wiring diagrams, process flow diagrams, and control system specifications.
   • Define system requirements and develop solutions that integrate PLCs with other industrial automation equipment such as SCADA, HMI, sensors, and actuators.

2. PLC Programming and Optimization:

   • Write, test, and optimize advanced PLC programs using industry-standard languages (e.g., Ladder Logic, Structured Text, Function Block Diagram).
   • Review, debug, and modify existing PLC programs to improve performance, reduce downtime, and optimize system efficiency.
   • Implement advanced control strategies and logic to meet complex process automation needs.
   • Lead the development and optimization of HMI/SCADA systems to ensure proper monitoring, control, and data logging of PLC-controlled processes.

3. Project Management and Leadership:

   • Lead and manage PLC-related automation projects from design to commissioning, ensuring projects are completed on time, within budget, and to specification.
   • Develop detailed project plans, including scope, schedule, budget, and resources, and monitor project performance to ensure alignment with goals.
   • Coordinate cross-functional teams (e.g., mechanical, electrical, and software engineering) to ensure seamless integration of PLC-based systems into larger projects.
   • Provide leadership in project meetings, ensuring that all team members are informed of project goals, timelines, and any issues or risks.

4. Troubleshooting and Advanced Issue Resolution:

   • Lead troubleshooting efforts for complex PLC, automation, and control system failures, ensuring minimal downtime and rapid recovery.
   • Perform root cause analysis for system faults, developing corrective actions and preventive measures to enhance system reliability.
   • Provide advanced technical support to internal teams and clients during system commissioning, troubleshooting, and optimization.

5. System Optimization and Performance Tuning:

   • Continuously monitor and analyze the performance of PLC systems, implementing improvements to enhance system functionality and reduce inefficiencies.
   • Drive initiatives to optimize the overall automation process, including reducing energy consumption, improving throughput, and minimizing downtime.
   • Analyze system performance data, identifying trends and areas for improvement, and implementing appropriate solutions.

6. Mentorship and Team Development:

   • Mentor and coach junior and mid-level PLC engineers and technicians, helping them develop technical skills and advance in their careers.
   • Lead training sessions and workshops on advanced PLC programming, system integration, troubleshooting techniques, and industry best practices.
   • Review the work of junior engineers, providing feedback and guidance to ensure high standards of quality and performance.

7. Safety and Regulatory Compliance:

   • Ensure that all PLC systems are designed, installed, and maintained in compliance with relevant safety standards, electrical codes (e.g., NEC, IEC), and industry regulations (e.g., OSHA).
   • Promote a safety-first culture, ensuring that all team members follow safety protocols and adhere to best practices during the design, installation, and maintenance of automation systems.
   • Lead safety audits and risk assessments to identify potential hazards and mitigate risks in automation system design and operation.

8. Collaboration and Cross-Functional Coordination:

   • Collaborate with project managers, engineers, and other departments to ensure that PLC-based control systems align with broader project goals and operational needs.
   • Work closely with external vendors, contractors, and clients to ensure that systems meet specifications and are delivered on time.
   • Serve as the primary technical point of contact for clients, stakeholders, and external teams involved in PLC projects.

9. Documentation and Reporting:

   • Ensure the creation and maintenance of thorough documentation for all PLC programming, system modifications, installation processes, and testing activities.
   • Generate detailed reports on system performance, troubleshooting, and corrective actions taken, providing clear insights to management and clients.
   • Ensure that project and system documentation is organized, accurate, and accessible for audits, inspections, and future upgrades.

10. Technology Innovation and Process Improvement:

    • Stay current with the latest trends and technologies in PLC programming, automation systems, and industrial control technologies.
    • Identify and implement new technologies, tools, and methodologies to improve system performance, efficiency, and cost-effectiveness.
    • Foster a culture of innovation within the team, encouraging the use of emerging technologies and approaches to improve automation and control processes.

Skills and Knowledge Required:

• Expert knowledge of PLC programming languages (e.g., Ladder Logic, Structured Text, Function Block Diagram), control systems, and automation technologies.
• In-depth understanding of industrial control systems, including PLCs, SCADA, HMI, sensors, actuators, and communication protocols (e.g., Modbus, Profibus, Ethernet/IP).
• Strong experience in troubleshooting and optimizing PLC systems, control panels, and automation systems.
• Proficiency in advanced system integration and process control strategies.
• Strong understanding of electrical codes, safety standards, and regulatory compliance (e.g., NEC, IEC, OSHA).
• Excellent problem-solving, analytical, and diagnostic skills for complex system issues.
• Proven leadership and team management skills, with experience mentoring and coaching junior engineers and technicians.
• Experience with project management, including budgeting, scheduling, and resource management.
• Ability to communicate effectively with internal teams, clients, vendors, and stakeholders.

Educational Qualifications:

• Bachelor’s or Master’s degree in Electrical Engineering, Control Systems Engineering, Electronics Engineering, or a related technical field.
• Certifications in PLC programming, industrial automation, or related areas (e.g., Siemens, Rockwell) are highly desirable.
• Additional certifications in project management (e.g., PMP) or safety (e.g., Six Sigma, OSHA) are a plus.

Experience:

• 7+ years of experience in PLC programming, automation systems, control systems engineering, or related fields.
• Proven experience in designing, troubleshooting, and optimizing PLC systems and industrial automation projects.
• Experience in leading teams, managing projects, and mentoring engineers in PLC and automation systems.

Tools and Technologies:

• Proficiency with PLC programming software (e.g., Siemens TIA Portal, Rockwell Studio 5000, Allen-Bradley).
• Experience with SCADA software (e.g., Wonderware, Ignition, Siemens WinCC) and HMI development tools.
• Familiarity with electrical design software and simulation tools (e.g., AutoCAD, MATLAB, LabVIEW).
• Knowledge of industrial communication protocols, network architecture, and cybersecurity best practices.

Other Requirements:

• Strong organizational, leadership, and time management skills to manage multiple projects and deadlines.
• Ability to work independently and as part of a team in a fast-paced, high-pressure environment.
• Willingness to travel to project sites, client locations, and supplier facilities as required.
• A proactive approach to problem-solving, continuous improvement, and technological innovation.