Job Title: Production Control Systems Engineer
Job Summary:
The Production Control Systems Engineering Manager is responsible for overseeing and managing the strategy, design, optimization, and operational integrity of production control systems in manufacturing environments. This role involves leading the integration of SCADA, PLC, MES (Manufacturing Execution Systems), and other control technologies to ensure production processes operate efficiently and meet quality standards. The manager will drive process improvements, optimize system performance, mentor the engineering team, and collaborate with senior leadership to align control systems with strategic business goals. This role requires strong leadership skills, technical expertise, and a focus on continuous improvement.
Key Responsibilities:
Strategic Leadership and Vision for Production Control Systems:
- Develop and implement the strategic roadmap for production control systems, ensuring alignment with company objectives and operational efficiency goals.
- Lead the design, integration, and continuous optimization of SCADA, PLC, and MES systems to enhance manufacturing productivity, quality, and process control.
- Evaluate and introduce new technologies and automation solutions to improve system performance and address evolving production needs.
Project Management and Execution:
- Manage large-scale projects related to the deployment and optimization of production control systems, ensuring they are completed on time, within budget, and meet operational requirements.
- Oversee the planning and execution of system upgrades, integrating new systems or technologies that enhance production workflows.
- Coordinate with cross-functional teams, including production, quality, maintenance, and IT, to ensure the smooth implementation and operation of new or upgraded systems.
Operational Efficiency and Continuous Improvement:
- Lead initiatives to drive continuous improvements in production efficiency, leveraging data from SCADA, PLC, and MES systems to identify bottlenecks and opportunities for system optimization.
- Implement Lean Manufacturing, Six Sigma, and other process improvement methodologies to streamline production processes, reduce waste, and enhance product quality.
- Ensure that control systems and automated processes are scalable and adaptable to changing production requirements and market demands.
Team Leadership and Development:
- Lead, mentor, and develop a team of engineers, fostering a culture of collaboration, innovation, and knowledge sharing.
- Provide technical leadership and guidance on system configuration, programming, troubleshooting, and optimization for junior and mid-level engineers.
- Set clear performance expectations, conduct performance reviews, and create development plans to ensure the growth and success of engineering team members.
Collaboration with Senior Leadership:
- Collaborate with senior leadership to align production control system goals with overall business objectives, ensuring that production systems contribute to business success and strategic growth.
- Present progress reports, performance metrics, and insights into system performance to senior management, highlighting opportunities for improvement or investment.
- Provide recommendations for future capital investment in control systems, automation technologies, and equipment.
Quality Assurance and Compliance:
- Ensure that all production control systems and automated processes comply with quality standards, regulatory requirements, and internal company policies.
- Work with quality assurance teams to establish and enforce quality control procedures, ensuring that systems consistently produce high-quality products.
- Oversee audits, system evaluations, and compliance checks to ensure that production control systems meet industry standards.
Maintenance and Troubleshooting Oversight:
- Oversee the routine maintenance, troubleshooting, and performance monitoring of production control systems to minimize downtime and prevent operational disruptions.
- Develop and enforce maintenance schedules, ensuring that all systems are proactively monitored and maintained for optimal performance.
- Lead complex troubleshooting efforts, resolving system performance issues and ensuring continuous production flow.
Risk Management and Problem Resolution:
- Identify and mitigate risks related to production control systems, including system failures, cybersecurity concerns, and operational bottlenecks.
- Develop contingency plans to address production delays, system failures, or equipment issues to ensure business continuity.
- Lead root cause analysis and corrective action initiatives for system-related problems to improve long-term performance.
Documentation and Reporting:
- Ensure comprehensive documentation for all production control systems, including system configurations, updates, maintenance records, and troubleshooting activities.
- Provide regular technical and operational reports to senior management, highlighting system performance, KPIs, and areas for improvement.
- Maintain clear records of system changes and updates to ensure regulatory compliance and transparency.
Technology Adoption and Innovation:
- Stay current with the latest trends in automation, control systems, and manufacturing technologies, recommending the adoption of innovative solutions that can improve production efficiency.
- Lead the adoption and integration of emerging technologies, ensuring that control systems are kept up-to-date and able to support future business needs.
Key Focus Areas:
- Strategic Production Control Systems Management: Lead the integration, optimization, and management of SCADA, PLC, and MES systems to drive operational efficiency and productivity.
- Project Leadership: Manage large-scale projects to deploy or upgrade control systems, ensuring timely execution and alignment with business goals.
- Operational Excellence and Process Optimization: Implement continuous improvement initiatives to enhance production workflows, reduce waste, and improve product quality.
- Team Leadership and Development: Mentor and guide a team of engineers, providing professional growth opportunities and fostering a collaborative work environment.
- Cross-Functional Collaboration: Work closely with senior management and other departments to align control systems with business objectives and enhance overall production efficiency.
Skills and Knowledge Required:
- Extensive experience with SCADA, PLC, and MES systems (e.g., Siemens, Allen-Bradley, Rockwell Automation).
- Strong understanding of production control, automation technologies, and manufacturing processes.
- Proven experience in managing and optimizing production control systems, including troubleshooting, programming, and system integration.
- Deep knowledge of Lean Manufacturing, Six Sigma, and other continuous improvement methodologies.
- Experience in project management, including managing budgets, resources, timelines, and risks for large-scale system deployments.
- Strong leadership and mentoring skills to guide and develop engineering teams.
- Excellent communication skills to collaborate with senior management and cross-functional teams.
- Knowledge of industry regulations, safety standards, and quality control procedures related to automated manufacturing.
Educational Qualifications:
- Bachelor’s or Master’s degree in Industrial Engineering, Automation Engineering, Electrical Engineering, Mechatronics, or a related technical field.
- Relevant certifications in PLC programming, SCADA systems, project management (e.g., PMP), and process optimization (e.g., Six Sigma, Lean) are highly desirable.
Experience:
- 10+ years of experience in production control systems engineering, automation, or related fields, with at least 3-5 years in a managerial or leadership role.
- Proven track record in managing large-scale automation projects and overseeing the deployment of production control systems.
- Extensive experience in leading teams, driving process improvements, and managing complex troubleshooting and system optimization tasks.
- Experience in a manufacturing or industrial environment is highly preferred.
Tools and Technologies:
- Proficiency with SCADA, PLC programming platforms, and MES (e.g., Siemens TIA Portal, Rockwell Studio 5000, Wonderware).
- Familiarity with industrial robotics, automation tools, and production scheduling systems.
- Knowledge of data analysis tools (e.g., Excel, SQL, data visualization software) and performance monitoring systems.
- Experience with manufacturing execution systems (MES) and enterprise resource planning (ERP) systems.
Other Requirements:
- Strong leadership and management capabilities, with experience in team development and project execution.
- Ability to make high-level technical decisions and communicate those decisions to senior leadership.
- A commitment to maintaining safety, quality, and operational excellence in all tasks.
- Willingness to travel to manufacturing sites, vendors, or project locations as needed.