Job Title: Process Automation and Control Engineer

Job Summary:

The Senior Process Automation and Control Engineer is responsible for overseeing and optimizing automated control systems in industrial processes. This role involves leading the design, integration, programming, and optimization of PLCs, SCADA systems, sensors, and other automation technologies to ensure the efficient and safe operation of complex processes. The Senior Engineer will lead troubleshooting and improvement initiatives, mentor junior engineers, and collaborate with cross-functional teams to enhance system performance, reduce downtime, and drive continuous improvements in automation and control systems.

Key Responsibilities:

1. Design and Integration of Automation Systems:

   • Lead the design, programming, and integration of complex automation systems, including PLCs, SCADA, HMI (Human-Machine Interface), and instrumentation.
   • Develop and configure control systems for large-scale industrial applications, ensuring optimal performance and seamless integration with other systems.
   • Provide expertise in the selection and integration of new automation technologies, ensuring they meet operational and regulatory standards.

2. Optimization and Continuous Improvement:

   • Analyze system data and performance metrics to identify inefficiencies and areas for optimization in automation processes.
   • Drive the optimization of control systems to improve operational efficiency, reduce waste, minimize downtime, and ensure process consistency.
   • Lead continuous improvement initiatives using lean methodologies, predictive analytics, and IoT technologies to enhance process control.

3. Troubleshooting and Issue Resolution:

   • Lead troubleshooting efforts for complex automation system issues, including PLC failures, sensor malfunctions, or control system bugs.
   • Provide in-depth technical support and problem-solving expertise to quickly resolve system outages or underperformance issues.
   • Perform root cause analysis for automation failures and implement corrective actions to prevent recurrence.

4. Project Management:

   • Manage and oversee automation projects from conception to execution, ensuring they meet timelines, budgets, and technical specifications.
   • Coordinate cross-functional teams, including engineering, operations, and maintenance, to implement automation solutions.
   • Oversee system commissioning, testing, and validation to ensure that all automation systems are fully integrated and operational.

5. Team Leadership and Mentorship:

   • Provide leadership and mentorship to junior and mid-level engineers, offering guidance in automation design, troubleshooting, and optimization.
   • Conduct training sessions and workshops to share best practices, new technologies, and system operation protocols.
   • Foster a collaborative environment within the team, promoting knowledge sharing and professional growth.

6. Regulatory Compliance and Safety:

   • Ensure that all automation systems comply with local, state, and federal regulations, including safety and environmental standards.
   • Develop and implement safety protocols for working with automated systems and electrical equipment.
   • Ensure that all automation projects and system upgrades adhere to relevant codes, regulations, and industry standards.

7. Data Management and Reporting:

   • Oversee the collection, analysis, and management of operational data from automation systems to ensure system performance and efficiency.
   • Develop key performance indicators (KPIs) and dashboards to monitor system health, track operational goals, and identify areas for improvement.
   • Prepare reports on system performance, optimization projects, and compliance with safety and regulatory standards for senior management.

8. Collaboration with Cross-Functional Teams:

   • Work closely with operations, engineering, IT, and maintenance teams to ensure the successful integration of automation systems into the plant’s workflow.
   • Collaborate with senior management to align automation objectives with overall business goals and strategies.
   • Support the implementation of new technologies, such as predictive maintenance or machine learning models, to improve the automation process.

9. Innovation and Technology Leadership:

   • Stay at the forefront of industry trends, emerging technologies, and innovations in process automation.
   • Identify opportunities to implement cutting-edge technologies like AI, machine learning, or Industry 4.0 in process automation and control systems.
   • Lead the exploration and adoption of new tools and technologies to improve system performance, increase automation efficiency, and reduce costs.

Skills and Knowledge Required:

• Expert knowledge of process automation systems, including PLC programming, SCADA, HMI, and industrial sensors.
• Strong proficiency in control system design, including the development and configuration of complex PLC control logic and integration with SCADA systems.
• In-depth understanding of industrial process control, including feedback loops, PID control, and sensor calibration.
• Proven ability to troubleshoot and resolve complex system issues, perform root cause analysis, and implement long-term solutions.
• Strong project management skills, including the ability to manage budgets, timelines, and cross-functional teams.
• Advanced data analysis skills, including experience with tools such as Power BI, SQL, Excel, or other data analytics platforms.
• Knowledge of industrial safety standards, environmental regulations, and best practices in process automation.

Educational Qualifications:

• Bachelor’s or Master’s degree in Electrical Engineering, Mechatronics, Automation Engineering, Industrial Engineering, or a related technical field.
• Advanced certifications in PLC programming, SCADA systems, or industrial automation are highly desirable.

Experience:

• 5+ years of experience in process automation, control systems, or industrial instrumentation, with a focus on designing, programming, and optimizing complex automation systems.
• Proven track record of leading automation projects, troubleshooting system failures, and implementing process improvements in industrial settings.
• Experience with SCADA systems, PLC programming (e.g., Siemens, Rockwell), and industrial instrumentation in manufacturing, utilities, or other industrial environments.

Tools and Technologies:

• Expertise in PLC programming software (e.g., Siemens TIA Portal, Rockwell Studio 5000).
• Experience with SCADA systems (e.g., Wonderware, Ignition, iFix) and industrial control systems.
• Familiarity with advanced data analytics tools (e.g., Power BI, SQL, Excel) and the application of machine learning or AI technologies in automation is a plus.

Other Requirements:

• Strong leadership, communication, and interpersonal skills to work effectively with cross-functional teams and management.
• Ability to work independently and as part of a team in a fast-paced environment.
• Strong problem-solving and analytical skills, with the ability to quickly address and resolve automation issues.
• Willingness to travel to different plant sites for project execution, troubleshooting, or system upgrades as required.