Job Title: PLC Programmer (Manufacturing)
Job Summary:
The PLC Programmer (Manufacturing) Manager is responsible for overseeing the strategic direction, design, development, optimization, and maintenance of PLC-based automation systems in manufacturing environments. This role involves leading a team of engineers to manage and enhance PLC programs, troubleshoot complex issues, and ensure that control systems are integrated effectively with other automation technologies such as SCADA, HMI, and MES systems. The PLC Manager will drive improvements in system efficiency, manage projects, mentor junior engineers, and collaborate with senior leadership to ensure that PLC-controlled systems align with business goals and production requirements.
Key Responsibilities:
Leadership in PLC Programming and Optimization:
- Lead the design, development, and optimization of PLC programs to automate manufacturing processes, ensuring that production systems are efficient, reliable, and meet quality standards.
- Oversee the troubleshooting, debugging, and optimization of PLC programs for complex systems, ensuring continuous production flow and minimal downtime.
- Provide technical leadership to the PLC programming team, ensuring the team follows best practices, standards, and guidelines in programming and system integration.
System Integration and Coordination:
- Lead the integration of PLC systems with SCADA, HMI, MES, and other automation technologies to create a seamless and effective control system across production lines.
- Ensure effective communication and data flow between PLCs, equipment, and other systems within the manufacturing environment to improve production processes.
- Manage system upgrades and new integrations, ensuring that PLC systems are compatible with evolving production requirements and technological advancements.
Project Management and Execution:
- Manage and oversee PLC programming projects, from the initial planning and design phases to execution, ensuring they are delivered on time, within budget, and according to specifications.
- Collaborate with cross-functional teams (e.g., production, maintenance, IT, and quality) to ensure smooth implementation of new PLC-controlled systems or upgrades.
- Monitor project progress, manage resources, and mitigate risks to ensure that project milestones and goals are met.
Troubleshooting and Maintenance Oversight:
- Lead efforts to diagnose and resolve complex PLC-related issues, minimizing system downtime and ensuring that production goals are met.
- Ensure that routine maintenance activities for PLC-controlled systems are performed to prevent failures and maintain operational efficiency.
- Establish and enforce maintenance schedules and processes to ensure that PLC systems are regularly checked, optimized, and updated.
Continuous Improvement and Process Optimization:
- Drive continuous improvement initiatives by identifying opportunities to optimize PLC programs, improve control systems, and streamline manufacturing processes.
- Leverage data from PLC systems, production metrics, and system performance analysis to propose and implement improvements.
- Use Lean Manufacturing, Six Sigma, and other methodologies to optimize production workflows and reduce waste.
Team Leadership and Development:
- Lead, mentor, and support a team of PLC programmers, providing technical guidance and fostering a culture of collaboration and continuous learning.
- Provide training and professional development opportunities to ensure that team members are up-to-date with the latest PLC programming techniques, automation technologies, and industry best practices.
- Conduct performance reviews, set team objectives, and align goals with the overall business and production strategies.
Documentation and Compliance:
- Ensure that all PLC programs, configurations, wiring diagrams, and troubleshooting logs are accurately documented and regularly updated.
- Maintain comprehensive documentation of system changes, upgrades, and troubleshooting activities to comply with company standards and regulatory requirements.
- Prepare reports for senior management that provide insights into system performance, production outcomes, and any technical challenges encountered.
Collaboration with Senior Leadership:
- Work with senior management to align PLC programming and automation strategies with the company’s broader business goals and production targets.
- Provide insights and recommendations to senior leadership on the adoption of new technologies or improvements in PLC-controlled systems to enhance production efficiency and meet business needs.
- Contribute to the long-term strategy for automation systems, helping guide decisions on capital investment, system upgrades, and process optimization.
Technology Adoption and Innovation:
- Stay updated on emerging trends and advancements in PLC programming, industrial automation, and manufacturing technologies.
- Evaluate new PLC hardware and software, recommending solutions that can improve system performance, reduce costs, or enhance flexibility in production.
- Lead initiatives to integrate new technologies or automation solutions into the existing manufacturing infrastructure.
Key Focus Areas:
- PLC Programming Leadership: Lead the development, optimization, and troubleshooting of PLC programs, ensuring efficient and reliable production systems.
- System Integration and Optimization: Ensure seamless integration of PLCs with SCADA, HMI, MES, and other automation technologies to improve production workflows.
- Project and Resource Management: Manage PLC programming projects, coordinating resources, timelines, and budgets for successful delivery.
- Continuous Improvement and Process Optimization: Drive ongoing optimization of PLC systems and manufacturing processes to increase efficiency and reduce operational costs.
- Team Leadership and Development: Mentor and develop a team of engineers, providing guidance, training, and fostering professional growth.
Skills and Knowledge Required:
- Extensive experience in PLC programming (e.g., Siemens, Allen-Bradley, Rockwell Automation), control systems, and industrial automation.
- Strong knowledge of SCADA, HMI, MES, and other automation technologies used in manufacturing systems.
- Expertise in troubleshooting and optimizing complex PLC systems and control equipment.
- Proven ability to manage large-scale projects, including managing resources, timelines, and budgets.
- Solid understanding of Lean Manufacturing, Six Sigma, and other process optimization methodologies.
- Strong leadership skills and the ability to guide and develop a team of engineers.
- Excellent communication and collaboration skills, with the ability to interact with senior management, cross-functional teams, and external stakeholders.
- Familiarity with industry regulations, safety standards, and best practices in automation and control systems.
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, project management (e.g., PMP), and process optimization (e.g., Six Sigma, Lean) are highly desirable.
Experience:
- 7+ years of experience in PLC programming, industrial automation, or control systems engineering, with at least 3-5 years in a managerial or leadership role.
- Proven track record in managing PLC programming projects, system integration, and troubleshooting in a manufacturing environment.
- Experience with SCADA, HMI, MES systems, and other automation technologies.
- Hands-on experience with industrial control systems, robotics, and production systems.
Tools and Technologies:
- Advanced proficiency with PLC programming software (e.g., Siemens TIA Portal, Rockwell Studio 5000, Mitsubishi GX Works).
- Familiarity with SCADA, HMI, and MES platforms (e.g., Wonderware, Ignition, Siemens).
- Knowledge of industrial control components such as sensors, actuators, robotics, and drives.
- Experience with data analysis tools and performance monitoring systems.
Other Requirements:
- Strong leadership and decision-making capabilities to manage teams and projects effectively.
- Ability to balance technical and operational priorities to meet production goals.
- Commitment to maintaining safety, quality, and operational excellence in all activities.
- Willingness to travel occasionally for project implementation, troubleshooting, or training.