Job Title: Process Automation and Control Engineer
Job Summary:
The Mid-Level Process Automation and Control Engineer is responsible for designing, implementing, and optimizing automated control systems in industrial settings. This role involves overseeing the installation, configuration, programming, and maintenance of PLCs, SCADA systems, sensors, and process control equipment. The engineer will collaborate with cross-functional teams to troubleshoot issues, improve system performance, and ensure the effective and safe operation of automation systems to meet operational goals and regulatory standards.
Key Responsibilities:
Process Automation and Control Systems Design:
- Lead the design and development of process automation systems, including PLC programming, SCADA configuration, and integration of sensors and control equipment.
- Customize and program control logic for PLCs to optimize industrial processes and ensure system efficiency.
- Work with senior engineers to integrate automation systems with existing control infrastructure, ensuring seamless operation and minimal disruption.
System Implementation and Integration:
- Oversee the installation and configuration of automation systems, ensuring they meet performance specifications and integrate properly with other control systems.
- Coordinate the commissioning of new systems, including the setup of SCADA systems, PLCs, and other instrumentation used for process control.
- Ensure the smooth integration of new automation technologies with legacy systems, performing system testing and validation.
Troubleshooting and Problem Solving:
- Lead troubleshooting efforts to identify and resolve complex issues with automated control systems, PLCs, sensors, and process control systems.
- Perform root cause analysis and implement corrective actions to minimize system downtime and improve overall system reliability.
- Provide technical support to operators and maintenance teams on automation systems, offering guidance on troubleshooting and system repairs.
Process Optimization and Efficiency Improvements:
- Analyze system data and operational performance to identify areas for improvement in automation processes.
- Optimize control systems to increase process efficiency, reduce energy consumption, minimize waste, and ensure that quality standards are met.
- Implement changes and upgrades to improve system functionality, safety, and performance.
Regulatory Compliance and Safety Standards:
- Ensure that all automation systems comply with industry regulations, safety standards, and environmental guidelines.
- Maintain proper documentation for control systems, including configuration settings, changes, and maintenance activities for compliance purposes.
- Ensure that automation systems are designed and maintained with safety in mind, including risk assessments and the implementation of safety protocols.
Project Management and Team Collaboration:
- Lead and manage automation projects, from design and implementation to optimization and troubleshooting.
- Collaborate with cross-functional teams, including operations, engineering, and maintenance, to ensure that automation systems meet operational goals.
- Coordinate with project teams to ensure that automation solutions are delivered on time, within budget, and meet technical specifications.
Training and Development:
- Mentor junior engineers and technicians, providing guidance on process automation, PLC programming, and troubleshooting techniques.
- Develop training materials and conduct training sessions for operators and maintenance teams to ensure proper system operation and maintenance.
- Stay updated on new developments in process automation and control systems, and incorporate new technologies and best practices into daily operations.
Continuous Improvement:
- Identify opportunities for continuous improvement in automation systems, applying lean principles and best practices to enhance process control.
- Work with senior engineers to implement new technologies such as predictive maintenance, IoT sensors, and advanced data analytics to improve system monitoring and performance.
Skills and Knowledge Required:
- Advanced understanding of process automation systems, including PLCs, SCADA, sensors, and control equipment.
- Proficiency in PLC programming and troubleshooting (e.g., Siemens TIA Portal, Rockwell Studio 5000).
- Experience with SCADA systems (e.g., Wonderware, Ignition) and their integration with process control systems.
- Strong analytical and problem-solving skills to identify, troubleshoot, and resolve system issues.
- Ability to optimize and improve process control systems to enhance efficiency and reduce operational costs.
- Knowledge of regulatory standards, safety guidelines, and best practices in process automation.
- Strong project management skills, including managing timelines, budgets, and cross-functional teams.
- Experience with data analysis and performance monitoring tools (e.g., Power BI, Excel, SQL).
Educational Qualifications:
- Bachelor’s degree in Electrical Engineering, Mechatronics, Automation Engineering, Industrial Engineering, or a related technical field.
- Certifications in process automation, PLC programming, SCADA systems, or industrial control systems are beneficial.
Experience:
- 3-5 years of experience in process automation, control systems, or industrial instrumentation, with hands-on experience in the design, programming, and maintenance of PLCs, SCADA systems, and other automation technologies.
- Proven experience in troubleshooting complex automation system issues and optimizing process control systems.
- Experience with industrial control systems in manufacturing, utilities, or similar industries is preferred.
Tools and Technologies:
- Proficiency in PLC programming software (e.g., Siemens TIA Portal, Rockwell Studio 5000).
- Experience with SCADA software (e.g., Wonderware, Ignition, iFix).
- Familiarity with data analysis tools and performance monitoring systems (e.g., Excel, Power BI, SQL).
- Knowledge of industrial automation technologies such as IoT sensors and predictive maintenance tools is a plus.
Other Requirements:
- Strong communication and teamwork skills to work effectively with cross-functional teams.
- Ability to manage multiple projects and prioritize tasks effectively in a fast-paced environment.
- Willingness to travel to sites for system installations, troubleshooting, or project coordination as needed.
- Strong attention to detail, ensuring high-quality results and compliance with safety standards.