Job Title: PLC Programmer (Manufacturing)

Job Summary:

The Mid-Level PLC Programmer (Manufacturing) is responsible for the development, optimization, and troubleshooting of Programmable Logic Controllers (PLCs) in automated manufacturing systems. This role involves taking the lead in programming, configuring, and integrating PLCs with other automation technologies such as SCADA, HMI, and MES systems. The PLC Programmer will collaborate with cross-functional teams to ensure smooth production operations, improve system performance, and resolve complex technical issues. This position provides the opportunity to further develop leadership skills, optimize manufacturing processes, and contribute to the overall efficiency of production systems.

Key Responsibilities:

1. PLC Programming and Optimization:

   • Develop and modify PLC programs for automation systems, including production lines, robotic systems, and material handling equipment.
   • Optimize PLC control logic to enhance system performance, improve production efficiency, and reduce downtime.
   • Troubleshoot, debug, and resolve complex PLC-related issues to ensure uninterrupted production operations.

2. System Integration and Configuration:

   • Lead the integration of PLC systems with SCADA, HMI, MES, and other industrial control systems to create seamless communication and data flow between manufacturing equipment.
   • Configure PLCs and other automation devices (sensors, actuators, drives) for optimal performance in the production environment.
   • Coordinate the setup and calibration of automated equipment, ensuring that PLC-controlled systems meet production requirements.

3. Production Monitoring and Troubleshooting:

   • Monitor PLC-controlled systems in real-time, ensuring that all equipment is functioning optimally and that production schedules are met.
   • Provide advanced troubleshooting support for complex issues related to PLC programs, electrical systems, and automation components.
   • Implement corrective actions for system faults, collaborating with production and maintenance teams to resolve issues promptly.

4. Continuous Improvement and Process Optimization:

   • Identify opportunities to improve production control systems by analyzing performance data and production metrics.
   • Lead initiatives to optimize existing PLC programs and automate processes to reduce waste, improve cycle times, and enhance system reliability.
   • Work with senior engineers to implement improvements and upgrades to PLC systems to meet evolving production demands.

5. Collaboration and Cross-Functional Support:

   • Collaborate with production, maintenance, quality assurance, and engineering teams to ensure that PLC systems align with operational goals and meet quality standards.
   • Provide technical support and guidance to production operators and maintenance teams on PLC programming, troubleshooting, and system operation.
   • Lead training sessions to educate staff on the efficient operation of PLC-controlled systems.

6. Documentation and Compliance:

   • Create and maintain detailed documentation for PLC programs, system configurations, wiring diagrams, and troubleshooting logs.
   • Ensure all system changes and updates are accurately documented, following internal procedures and compliance standards.
   • Prepare reports on system performance, project progress, and technical issues for management review.

7. Project Management and Leadership:

   • Lead or assist in the execution of PLC programming and automation projects, ensuring they are delivered on time and meet technical specifications.
   • Manage project timelines, resources, and documentation to ensure project objectives are met.
   • Guide and mentor junior PLC programmers, offering advice and technical support on complex programming tasks.

8. Learning and Development:

   • Stay updated with the latest developments in PLC programming, industrial automation, and manufacturing technologies.
   • Participate in training programs and workshops to enhance technical skills and knowledge in automation systems.
   • Apply new knowledge and best practices to optimize production control systems and improve manufacturing processes.

Key Focus Areas:

• PLC Programming and System Optimization: Lead the development and optimization of PLC programs for manufacturing automation systems.
• System Integration: Integrate PLC systems with SCADA, HMI, and MES for seamless automation and data communication.
• Troubleshooting and Maintenance: Provide expert troubleshooting and maintenance support for PLC-controlled systems to ensure efficient production.
• Continuous Improvement: Identify and implement continuous improvements to enhance the performance and reliability of production control systems.
• Collaboration and Team Leadership: Work closely with cross-functional teams and mentor junior engineers in PLC programming and automation technologies.

Skills and Knowledge Required:

• Strong knowledge of PLC programming languages (e.g., Ladder Logic, Structured Text, Function Block Diagram).
• Experience with PLC programming software (e.g., Siemens TIA Portal, Rockwell Studio 5000, Mitsubishi GX Works).
• In-depth understanding of industrial automation systems, including SCADA, HMI, sensors, actuators, and robotics.
• Experience in troubleshooting and resolving complex PLC-related issues in a manufacturing environment.
• Ability to analyze performance data and implement process optimization strategies.
• Excellent communication and teamwork skills to collaborate with various departments and mentor junior engineers.
• Strong problem-solving skills and attention to detail in technical tasks.

Educational Qualifications:

• Bachelor’s degree in Electrical Engineering, Automation Engineering, Mechatronics, Industrial Engineering, or a related technical field.
• Certifications in PLC programming, automation systems, or industrial control (e.g., Siemens, Rockwell Automation) are a plus.

Experience:

• 3-5 years of experience in PLC programming, industrial automation, or related fields, preferably in a manufacturing environment.
• Proven experience in troubleshooting and optimizing PLC-controlled systems.
• Experience with system integration, including SCADA, HMI, and MES systems, is highly desirable.
• Experience in mentoring or leading teams, and working on projects related to PLC programming and automation systems.

Tools and Technologies:

• Proficiency with PLC programming software (e.g., Siemens TIA Portal, Rockwell Studio 5000, Mitsubishi GX Works).
• Experience with SCADA, HMI, and MES systems (e.g., Wonderware, Ignition, Siemens).
• Knowledge of industrial control components, such as sensors, actuators, and robotics.
• Familiarity with data analysis tools and diagnostic software for performance monitoring.

Other Requirements:

• Strong leadership skills and the ability to mentor and guide junior engineers.
• Ability to handle multiple projects and tasks in a fast-paced manufacturing environment.
• Commitment to maintaining safety standards, quality control, and operational excellence.
• Willingness to travel occasionally for project implementation, troubleshooting, or training.