Job Title: Process Control Technician
Job Summary:
The Mid-Level Process Control Technician is responsible for overseeing and optimizing the performance of process control systems and instrumentation used in manufacturing environments. This role involves ensuring that process control systems operate efficiently, troubleshooting complex issues, conducting regular maintenance and calibration of control equipment, and supporting the integration of new automation technologies. The technician will collaborate with engineers and production teams to improve system reliability, ensure adherence to quality standards, and contribute to the overall efficiency of production processes.
Key Responsibilities:
Process Control System Maintenance and Optimization:
- Oversee the setup, calibration, maintenance, and optimization of process control systems, including PLCs, sensors, actuators, and control valves.
- Ensure control systems are performing at optimal levels to meet production goals and safety standards.
- Analyze system performance data, identify inefficiencies or issues, and implement corrective actions to enhance the performance and reliability of control systems.
Troubleshooting and Problem Resolution:
- Provide advanced troubleshooting support for complex issues related to process control systems, instrumentation, and automation equipment.
- Work closely with engineers to diagnose and resolve faults in PLCs, SCADA systems, sensors, and other control devices.
- Conduct root cause analysis of process failures, propose solutions, and ensure corrective actions are implemented effectively.
Process Control System Integration and Upgrades:
- Assist in the integration of new process control systems and automation technologies into existing production lines to improve system functionality and efficiency.
- Coordinate system upgrades, ensuring minimal disruption to production operations while ensuring new systems meet production specifications.
- Provide technical support during system integration and support the commissioning of new equipment.
Monitoring and Data Collection:
- Continuously monitor the performance of PLC-controlled systems and other automation systems to ensure smooth production operations.
- Collect, analyze, and report performance data to identify trends, system failures, or opportunities for optimization.
- Develop and maintain reports on system performance, downtime, and any changes made to control systems.
Collaboration with Cross-Functional Teams:
- Work closely with production, quality, and maintenance teams to address issues related to process control and ensure that production goals are met.
- Provide support for operators in understanding and using control systems effectively, ensuring they follow best practices and safety procedures.
- Communicate technical issues clearly to management and provide solutions to optimize operational efficiency.
Training and Development:
- Provide guidance and mentorship to junior technicians, helping them troubleshoot and maintain control systems.
- Assist in the training of operators and maintenance staff on the operation and troubleshooting of process control systems.
- Participate in training programs and workshops to enhance technical skills and knowledge of new technologies.
Documentation and Compliance:
- Maintain accurate and up-to-date documentation of system configurations, calibration logs, troubleshooting activities, and maintenance records.
- Ensure that process control systems comply with industry standards, safety regulations, and internal quality standards.
- Prepare technical reports on process control systems, including performance evaluations and recommendations for improvements.
Safety and Quality Assurance:
- Ensure that all process control activities are conducted safely and in compliance with safety regulations.
- Maintain a high standard of quality assurance by ensuring that process control systems consistently produce high-quality outputs.
- Implement safety protocols to prevent equipment failures or process disruptions that could affect production safety or product quality.
Key Focus Areas:
- Process Control System Optimization: Oversee the maintenance and optimization of PLC-controlled systems and other control devices.
- Troubleshooting and Maintenance: Lead efforts to diagnose and resolve complex technical issues in process control systems.
- System Integration and Upgrades: Support the integration and commissioning of new process control systems to improve operational efficiency.
- Collaboration and Support: Work with cross-functional teams to ensure smooth production operations and optimize process control systems.
- Learning and Development: Mentor junior technicians and participate in training to stay updated with new technologies and best practices.
Skills and Knowledge Required:
- Strong understanding of process control systems, PLC programming, instrumentation, and automation technologies.
- Experience in troubleshooting and resolving complex process control issues in manufacturing environments.
- Proficiency in data collection, analysis, and performance monitoring tools for process control systems.
- Familiarity with SCADA, HMI, and MES systems is a plus.
- Knowledge of industry standards, safety regulations, and quality control procedures related to process control and automation.
- Ability to collaborate effectively with engineers, production teams, and maintenance personnel.
- Strong problem-solving skills and attention to detail when diagnosing system issues and implementing solutions.
- Good communication skills to report technical findings and collaborate with cross-functional teams.
Educational Qualifications:
- Associate's or Bachelor's degree in Electrical Engineering, Automation Engineering, Mechatronics, Industrial Engineering, or a related technical field.
- Certifications in PLC programming, process control, industrial automation, or control systems are advantageous.
Experience:
- 3-5 years of experience working in process control, instrumentation, or automation systems in a manufacturing or industrial environment.
- Proven experience with troubleshooting PLC-controlled systems, sensors, actuators, and other industrial automation equipment.
- Experience with SCADA systems, HMI, and MES systems is desirable.
- Hands-on experience with maintenance, calibration, and optimization of process control systems.
Tools and Technologies:
- Experience with PLC programming platforms (e.g., Siemens, Rockwell Automation, Mitsubishi).
- Familiarity with SCADA systems, HMI, MES, and other automation platforms.
- Proficiency in diagnostic and maintenance tools, including multimeters, oscilloscopes, and diagnostic software.
- Knowledge of process control software and performance monitoring systems.
Other Requirements:
- Strong leadership and mentoring capabilities to guide junior technicians and support team development.
- Ability to manage multiple tasks and projects in a fast-paced environment while meeting deadlines.
- Commitment to safety, quality, and continuous improvement in all activities.
- Willingness to participate in on-call shifts or respond to system issues outside of regular working hours.