Job Title: Process Control Technician
Job Summary:
The Senior Process Control Technician is responsible for overseeing and optimizing process control systems in manufacturing environments. This role involves managing the configuration, troubleshooting, maintenance, and continuous improvement of PLC-based control systems, instrumentation, and automation technologies. The Senior Technician will lead the implementation of process control strategies, mentor junior technicians, ensure that systems run efficiently, and collaborate with engineers to improve system performance and meet production goals. The Senior Process Control Technician plays a critical role in maintaining system reliability, driving operational efficiency, and ensuring quality control in manufacturing processes.
Key Responsibilities:
Leadership in Process Control Systems Optimization:
- Oversee the setup, configuration, and optimization of complex process control systems, including PLCs, SCADA, sensors, actuators, and control valves.
- Lead the troubleshooting and debugging of process control systems, resolving complex issues that affect system performance and production efficiency.
- Work with senior engineers to continuously improve the functionality of control systems, ensuring they are aligned with production goals, safety standards, and regulatory requirements.
Troubleshooting and Problem Resolution:
- Lead the identification and resolution of complex issues in process control systems, including PLC malfunctions, instrumentation failures, and control system inconsistencies.
- Perform advanced diagnostics and root cause analysis of process failures, ensuring corrective actions are implemented promptly to minimize downtime.
- Collaborate with production, maintenance, and engineering teams to troubleshoot issues effectively and ensure that the systems are functioning optimally.
System Integration and Automation:
- Lead efforts to integrate PLC-controlled systems with other automation technologies (e.g., SCADA, HMI, MES) to enhance process control, data collection, and system communication.
- Oversee the commissioning and installation of new process control systems, ensuring that they are integrated smoothly with existing production equipment.
- Ensure that automated systems are scalable, reliable, and adaptable to future changes in production requirements.
Process Monitoring and Data Analysis:
- Monitor process control systems and ensure that they operate within optimal parameters, tracking key performance indicators (KPIs) and production data.
- Analyze process data to identify trends, inefficiencies, or areas for improvement in system performance, making recommendations to optimize production efficiency.
- Generate reports on system performance, including downtime, troubleshooting activities, and key metrics for management and quality assurance teams.
Mentorship and Team Leadership:
- Mentor and provide technical guidance to junior and mid-level process control technicians, helping them improve their troubleshooting skills and understanding of control systems.
- Lead training sessions for technicians and operators on the efficient use of process control systems, troubleshooting techniques, and safety procedures.
- Ensure that team members follow standard operating procedures (SOPs) and comply with safety regulations when working with process control systems.
Continuous Improvement and Process Optimization:
- Drive continuous improvement initiatives in process control systems by identifying inefficiencies, bottlenecks, and opportunities to reduce waste or downtime.
- Implement Lean Manufacturing and Six Sigma methodologies to optimize manufacturing processes and improve system reliability.
- Lead projects to upgrade or replace outdated systems and implement new technologies to improve control and automation capabilities.
Safety and Quality Assurance:
- Ensure all process control systems and related activities comply with industry safety standards, environmental regulations, and quality assurance requirements.
- Monitor control systems to ensure consistent product quality and identify any issues that could affect the safety or quality of the manufacturing process.
- Work closely with the quality control team to ensure that all process control systems meet production standards and specifications.
Documentation and Reporting:
- Maintain accurate documentation for all system configurations, calibration records, maintenance logs, and troubleshooting activities.
- Prepare technical reports, including analysis of system performance, downtime, and efficiency improvements, for senior management.
- Ensure that all modifications to process control systems are documented and comply with company standards and regulatory requirements.
Collaboration with Cross-Functional Teams:
- Collaborate with engineering, production, quality assurance, and maintenance teams to ensure that process control systems are effectively integrated into overall production operations.
- Participate in cross-functional meetings to discuss system upgrades, process improvements, and any issues impacting system performance.
Key Focus Areas:
- Process Control System Optimization: Lead the optimization, maintenance, and troubleshooting of PLC-controlled systems and related automation technologies.
- System Integration and Troubleshooting: Manage complex integration projects and troubleshoot system issues, ensuring efficient production and minimal downtime.
- Continuous Improvement: Drive initiatives to improve system performance, process efficiency, and overall production output.
- Team Leadership and Mentorship: Provide leadership and mentorship to junior technicians, fostering growth and development in process control and automation technologies.
- Safety and Compliance: Ensure compliance with safety standards, quality control procedures, and regulatory requirements in process control operations.
Skills and Knowledge Required:
- Advanced knowledge of process control systems, including PLC programming, industrial instrumentation, and automation technologies.
- Extensive experience troubleshooting complex control systems, instrumentation, and automated equipment in manufacturing environments.
- Strong analytical and problem-solving skills, with the ability to perform root cause analysis and implement corrective actions.
- In-depth understanding of SCADA, HMI, MES, and other control systems used in manufacturing.
- Expertise in process optimization and the application of Lean Manufacturing, Six Sigma, or other process improvement methodologies.
- Excellent communication skills, with the ability to mentor junior technicians and collaborate with cross-functional teams.
- Strong project management skills, with experience managing system upgrades, integrations, and continuous improvement initiatives.
Educational Qualifications:
- 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 highly desirable.
Experience:
- 5+ years of experience in process control, instrumentation, or automation systems in a manufacturing or industrial environment.
- Proven experience troubleshooting and optimizing PLC-controlled systems, instrumentation, and automated equipment.
- Extensive experience in process integration, system upgrades, and working with cross-functional teams to optimize manufacturing operations.
Tools and Technologies:
- Expertise with PLC programming platforms (e.g., Siemens, Rockwell Automation, Mitsubishi).
- Experience with SCADA, HMI, and MES systems (e.g., Wonderware, Ignition, Siemens).
- Familiarity with industrial control components such as sensors, actuators, robotics, and drives.
- Experience with data collection, performance monitoring tools, and diagnostic software for process control systems.
Other Requirements:
- Strong leadership abilities, with experience mentoring and guiding teams of technicians and engineers.
- Ability to manage multiple projects and initiatives in a fast-paced environment while ensuring high-quality results.
- Commitment to safety, quality, and operational excellence in all aspects of process control.
- Willingness to travel as necessary to support system installation, troubleshooting, or training.