Job Title: Process Control Technician Supervisor
Job Summary:
The Process Control Technician Supervisor is responsible for overseeing the day-to-day operations of the process control team in a manufacturing environment. This role involves managing the performance, maintenance, and optimization of process control systems, including PLCs, SCADA, HMI, and MES systems. The Supervisor will lead and mentor a team of process control technicians, ensuring that systems run efficiently, downtime is minimized, and production goals are met. This position requires a strong technical background, leadership skills, and the ability to collaborate with other departments to optimize manufacturing processes and maintain quality standards.
Key Responsibilities:
Team Leadership and Supervision:
- Supervise, lead, and mentor a team of process control technicians, providing guidance on troubleshooting, system maintenance, and optimization.
- Assign tasks and prioritize activities for team members to ensure the effective operation of process control systems and timely resolution of issues.
- Conduct regular performance reviews, provide feedback, and support the development of junior technicians through training and professional growth opportunities.
- Foster a positive team culture, ensuring good communication and collaboration across the team and other departments.
Process Control System Management:
- Oversee the setup, calibration, and maintenance of process control systems, including PLCs, SCADA, HMI, and other automation technologies.
- Ensure that process control systems operate within optimal parameters and support manufacturing processes efficiently, minimizing downtime and meeting production goals.
- Lead troubleshooting efforts for complex system issues and provide support for minor issues in the team.
System Integration and Improvement:
- Coordinate the integration of new process control systems, equipment, and automation technologies into the manufacturing process.
- Collaborate with engineering teams to implement system improvements, upgrades, and new technologies aimed at increasing system efficiency, reliability, and scalability.
- Use data analysis and performance metrics to identify opportunities for continuous improvement in process control systems.
Quality Control and Safety Compliance:
- Ensure that process control systems adhere to safety standards, regulatory requirements, and internal quality protocols.
- Work closely with quality assurance and safety teams to implement and enforce quality control procedures to maintain high standards of production quality.
- Lead efforts to maintain a safe working environment, ensuring all team members follow safety guidelines and use equipment responsibly.
Monitoring and Data Analysis:
- Oversee the collection and analysis of data from process control systems, monitoring key performance indicators (KPIs) such as system efficiency, downtime, and production output.
- Provide regular reports on system performance, maintenance activities, and troubleshooting results to senior management.
- Analyze trends and use performance data to proactively identify potential issues, inefficiencies, or areas for improvement in control systems.
Collaboration with Cross-Functional Teams:
- Collaborate with production, maintenance, engineering, and quality assurance teams to ensure smooth production operations and effective use of process control systems.
- Coordinate with other departments to plan and execute system upgrades, modifications, or new installations.
- Communicate effectively with management regarding the status of process control systems, including any issues or opportunities for improvement.
Training and Development:
- Develop training programs for the process control team to enhance technical knowledge and troubleshooting skills.
- Ensure that all team members are properly trained on new equipment, systems, and safety procedures.
- Stay updated on the latest technologies in process control and automation, and train the team on the latest developments.
Preventive and Corrective Maintenance:
- Oversee the preventive maintenance schedule for process control systems and equipment, ensuring all systems are regularly checked and optimized for performance.
- Lead the team in corrective maintenance activities, addressing issues that arise quickly and efficiently to minimize production interruptions.
Budget and Resource Management:
- Manage resources and materials for process control activities, ensuring that the team has the necessary tools, parts, and supplies to perform their tasks effectively.
- Assist in the management of the department's budget, ensuring that activities are cost-effective and that expenses are kept within allocated limits.
Key Focus Areas:
- Team Leadership and Supervision: Lead, guide, and support the process control technician team, ensuring effective operation and performance.
- System Optimization and Troubleshooting: Oversee the maintenance and optimization of PLC-controlled systems, troubleshooting complex issues and minimizing downtime.
- Collaboration and Communication: Ensure effective communication and collaboration between process control teams and other departments, including production, maintenance, and engineering.
- Quality and Safety Compliance: Ensure adherence to quality standards, safety regulations, and process optimization strategies to meet production goals.
- Continuous Improvement: Drive continuous improvement initiatives to enhance system efficiency, reliability, and overall manufacturing performance.
Skills and Knowledge Required:
- Strong understanding of PLC programming, process control systems, industrial automation, and instrumentation.
- Experience with SCADA, HMI, MES systems, and other automation technologies used in manufacturing environments.
- Proven experience leading and supervising teams, with strong leadership, mentoring, and communication skills.
- Ability to troubleshoot and resolve complex technical issues related to process control systems.
- Knowledge of safety regulations, quality control standards, and maintenance practices in industrial environments.
- Strong analytical and problem-solving skills, with the ability to use data to drive process improvements.
- Experience with Lean Manufacturing, Six Sigma, or other continuous improvement methodologies.
Educational Qualifications:
- Bachelor’s degree in Electrical Engineering, Automation Engineering, Mechatronics, Industrial Engineering, or a related technical field.
- Certifications in PLC programming, industrial automation, or process control are a plus.
Experience:
- 5+ years of experience in process control, industrial automation, or related fields, with at least 2-3 years in a supervisory or leadership role.
- Proven experience with PLC-controlled systems, troubleshooting, and optimizing process control equipment in a manufacturing environment.
- Experience with managing teams, coordinating cross-functional projects, and overseeing maintenance activities.
Tools and Technologies:
- Advanced proficiency with PLC programming platforms (e.g., Siemens, Rockwell Automation, Mitsubishi).
- Experience with SCADA, HMI, MES systems, and industrial automation software.
- Familiarity with diagnostic and performance monitoring tools used for troubleshooting process control systems.
Other Requirements:
- Strong leadership and decision-making abilities to manage and guide a team.
- Ability to prioritize tasks, manage time effectively, and work under pressure in a fast-paced manufacturing environment.
- Commitment to maintaining safety standards, quality control procedures, and operational excellence.
- Willingness to work flexible hours, including on-call shifts, to address system issues and ensure continuous production.