Job Title: PLC Programmer (Manufacturing)
Job Summary:
The Senior PLC Programmer (Manufacturing) is responsible for overseeing the design, development, optimization, and maintenance of PLC programs within an automated manufacturing environment. This role involves managing complex control systems, optimizing production lines, and integrating PLCs with other automation technologies, such as SCADA, HMI, and MES systems. The Senior PLC Programmer will lead projects, mentor junior engineers, troubleshoot critical issues, and drive continuous improvements in system performance. This role requires both advanced technical expertise and strong leadership abilities to ensure that manufacturing systems operate efficiently, reliably, and meet production goals.
Key Responsibilities:
Advanced PLC Programming and Optimization:
- Lead the design, development, and modification of PLC programs to automate and optimize manufacturing systems, including production lines, robotic systems, and material handling equipment.
- Implement complex control logic and system configurations to improve production efficiency, quality, and safety.
- Oversee the troubleshooting, debugging, and optimization of PLC programs to ensure high system reliability and minimal downtime.
System Integration and Coordination:
- Manage the integration of PLCs with SCADA, HMI, MES, and other control systems to ensure seamless communication between different automation components.
- Ensure that all systems work together effectively, providing a smooth, unified control interface for production processes.
- Oversee the setup and calibration of PLC-controlled equipment to ensure they meet production and operational specifications.
Project Leadership and Execution:
- Lead and manage PLC programming projects, from initial design through implementation, ensuring projects are completed on time and within budget.
- Coordinate with cross-functional teams, including production, maintenance, quality, and IT departments, to ensure the successful deployment of new systems or upgrades.
- Manage project timelines, resources, and budgets, and provide regular updates to senior management on project progress.
Troubleshooting and Maintenance Oversight:
- Take ownership of critical troubleshooting efforts related to PLC-controlled systems, ensuring rapid resolution of any issues that arise in production.
- Guide teams in resolving complex problems with PLCs, including electrical faults, communication failures, and control system anomalies.
- Ensure ongoing maintenance and calibration of PLC-controlled systems to prevent unplanned downtime and optimize system performance.
Continuous Improvement and Process Optimization:
- Analyze system performance data from PLCs, SCADA, and MES to identify areas for improvement in manufacturing processes.
- Drive continuous improvement initiatives, including optimizing PLC programs, enhancing system reliability, and increasing production efficiency.
- Lead process optimization initiatives using Lean Manufacturing, Six Sigma, or other methodologies to enhance production workflows and reduce waste.
Mentorship and Team Leadership:
- Mentor and provide guidance to junior and mid-level PLC programmers, helping them grow their technical skills and develop their careers.
- Lead training sessions to upskill team members in PLC programming and automation best practices.
- Ensure that best practices in programming, troubleshooting, and documentation are followed by all engineers in the team.
Documentation and Compliance:
- Ensure that all PLC programs, system configurations, wiring diagrams, and troubleshooting logs are accurately documented and updated.
- Maintain documentation in compliance with industry standards, regulatory requirements, and company policies.
- Prepare technical reports and performance evaluations to communicate system performance and project outcomes to senior management.
Collaboration with Cross-Functional Teams:
- Work closely with other engineering teams, including electrical, mechanical, and software engineers, to integrate PLC systems with other automation equipment.
- Collaborate with quality assurance teams to ensure that PLC systems meet required standards for safety, quality, and production efficiency.
- Provide technical expertise and support to operations and maintenance teams in troubleshooting and maintaining PLC systems.
Technology Evaluation and Innovation:
- Stay current with emerging technologies in PLC programming, automation systems, and manufacturing processes.
- Evaluate and recommend new PLC hardware, software, and technologies that can enhance automation capabilities, improve system performance, or reduce operational costs.
- Lead efforts to implement new technologies that improve production flexibility, scalability, and system integration.
Key Focus Areas:
- Advanced PLC Programming and Optimization: Lead the design, development, and optimization of PLC programs to improve manufacturing efficiency and system reliability.
- System Integration and Troubleshooting: Ensure seamless integration of PLCs with SCADA, HMI, and MES, while leading complex troubleshooting efforts to resolve critical system issues.
- Project Management: Lead PLC programming projects from initiation to completion, managing resources, timelines, and budgets.
- Mentorship and Team Leadership: Guide junior and mid-level engineers, fostering a culture of learning and improvement within the team.
- Continuous Improvement and Innovation: Drive process optimization and technological innovation to continuously enhance production control systems.
Skills and Knowledge Required:
- Expert-level knowledge of PLC programming languages (e.g., Ladder Logic, Structured Text, Function Block).
- Strong 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, MES, and other automation equipment.
- Extensive experience in troubleshooting and resolving complex PLC-related issues in a manufacturing environment.
- Strong knowledge of manufacturing processes, production systems, and process optimization.
- Proven leadership and project management skills, with the ability to lead cross-functional teams and manage large-scale projects.
- Strong problem-solving and analytical skills, with the ability to think critically and act quickly in high-pressure situations.
- Excellent communication skills, with the ability to provide clear instructions, reports, and presentations to senior management and cross-functional teams.
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, industrial automation, project management (e.g., PMP), or process optimization (e.g., Six Sigma, Lean) are highly desirable.
Experience:
- 5+ years of experience in PLC programming, industrial automation, or control systems engineering, with at least 2-3 years in a senior or leadership role.
- Proven experience in troubleshooting and optimizing PLC-controlled systems in a manufacturing or industrial environment.
- Strong experience in managing PLC programming projects, including system integration, testing, and implementation.
- Hands-on experience with SCADA, HMI, and MES systems, as well as knowledge of manufacturing processes and automation technologies.
Tools and Technologies:
- Proficiency with PLC programming platforms (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 and diagnostic tools used for performance monitoring and troubleshooting.
Other Requirements:
- Strong leadership and decision-making capabilities, with the ability to manage and guide teams.
- Ability to manage multiple projects and priorities in a fast-paced manufacturing environment.
- A commitment to maintaining safety, quality, and operational excellence in all tasks and activities.
- Willingness to travel as necessary to support system implementation, troubleshooting, or training.