Job Title: Production Control Systems Engineer

Job Summary:

The Mid-Level Production Control Systems Engineer is responsible for managing and optimizing production control systems in a manufacturing environment. This role involves overseeing the setup, integration, and operation of SCADA, PLC, and Manufacturing Execution Systems (MES) to monitor, control, and optimize production processes. The engineer will work closely with cross-functional teams to ensure smooth production flow, resolve complex system issues, improve production efficiency, and ensure systems are fully aligned with production goals. This position also offers leadership opportunities to mentor junior engineers and drive continuous improvements in production control systems.

Key Responsibilities:

1. Production Control Systems Management and Optimization:

   • Oversee the setup, configuration, and optimization of SCADA, PLC, and MES systems used to control and monitor production processes.
   • Lead efforts to integrate control systems with automated equipment, ensuring that production lines operate efficiently and without disruptions.
   • Continuously monitor system performance, identifying areas for improvement, and implementing changes to enhance the efficiency and reliability of production control systems.

2. SCADA and PLC Programming and Troubleshooting:

   • Develop, modify, and optimize PLC programs and SCADA configurations to improve system performance and ensure alignment with production goals.
   • Troubleshoot and resolve complex issues with PLC and SCADA systems, minimizing downtime and ensuring smooth production processes.
   • Work with production teams to ensure that control systems are working as expected and meet operational requirements.

3. Production Scheduling and Coordination:

   • Manage and optimize production schedules using MES and other production control tools to meet production targets and minimize downtime.
   • Work with production, planning, and logistics teams to ensure that resources (materials, machinery, personnel) are available and used efficiently.
   • Adjust production schedules based on real-time data from production control systems to meet changing priorities and operational challenges.

4. Data Collection, Analysis, and Reporting:

   • Collect and analyze data from production systems, equipment, and control systems to monitor performance and identify trends or inefficiencies.
   • Generate regular reports on system performance, production outcomes, and key performance indicators (KPIs) for senior management.
   • Use data insights to recommend changes to production processes, control systems, or scheduling practices to improve efficiency.

5. System Maintenance and Continuous Improvement:

   • Lead routine maintenance of production control systems and equipment to ensure optimal performance and prevent unplanned downtime.
   • Identify and implement system improvements, driving initiatives to enhance system reliability, reduce waste, and increase overall productivity.
   • Foster a culture of continuous improvement by leveraging Lean Manufacturing, Six Sigma, and other process optimization methodologies.

6. Team Collaboration and Leadership:

   • Collaborate with production teams, quality assurance, and maintenance departments to ensure the seamless operation of production control systems and equipment.
   • Provide leadership and technical guidance to junior engineers, offering mentorship and support in the troubleshooting and optimization of control systems.
   • Participate in meetings with cross-functional teams to discuss production schedules, issues, and solutions to improve workflow and system performance.

7. Project Management and Execution:

   • Manage and lead projects to improve or implement new production control systems, ensuring that projects are delivered on time, within scope, and on budget.
   • Coordinate with vendors, suppliers, and contractors for the procurement and installation of new control systems or equipment.
   • Ensure that all project milestones are met and that the transition to new systems or updates is smooth.

8. Quality Assurance and Compliance:

   • Ensure that production control systems meet all quality standards and regulatory requirements.
   • Monitor production lines to ensure that control systems maintain consistent quality levels in line with production specifications.
   • Collaborate with quality assurance teams to develop and enforce quality control measures for automated systems.

9. Documentation and Reporting:

   • Maintain accurate and up-to-date documentation for production control systems, including system configurations, programming changes, and maintenance logs.
   • Provide regular updates on system performance, project progress, and operational challenges to senior management.
   • Ensure all changes to control systems are well-documented for future reference and audits.

Key Focus Areas:

• Production Control Systems Management: Lead the optimization and management of SCADA, PLC, and MES systems to ensure efficient and reliable production processes.
• SCADA/PLC Programming and Troubleshooting: Develop and optimize control systems to improve production line performance and minimize downtime.
• Data-Driven Process Improvement: Collect and analyze performance data to drive continuous improvement initiatives and optimize production workflows.
• Team Leadership: Mentor junior engineers and collaborate with cross-functional teams to drive efficiency and problem resolution.
• Project Management: Manage projects for system upgrades, improvements, or installations to meet operational needs.

Skills and Knowledge Required:

• Strong experience in SCADA, PLC programming, and MES systems (e.g., Siemens, Allen-Bradley, Rockwell Automation).
• Proficiency in troubleshooting and resolving complex issues in automation and control systems.
• Knowledge of production control, manufacturing processes, and production scheduling practices.
• Strong analytical skills, with the ability to identify trends, performance issues, and areas for improvement.
• Ability to work with cross-functional teams and provide technical guidance to junior engineers.
• Familiarity with Lean Manufacturing, Six Sigma, and other continuous improvement methodologies.
• Excellent problem-solving, project management, and communication skills.

Educational Qualifications:

• Bachelor’s degree in Industrial Engineering, Automation Engineering, Electrical Engineering, Mechatronics, or a related technical field.
• Relevant certifications in PLC programming, SCADA systems, or Manufacturing Execution Systems (MES) is highly desirable.

Experience:

• 3-5 years of experience in production control systems engineering or a related field.
• Proven experience in the optimization, programming, and troubleshooting of SCADA, PLC, and MES systems in manufacturing environments.
• Experience in project management, including leading projects and coordinating cross-functional teams.
• Hands-on experience with automated manufacturing equipment and production scheduling systems is an advantage.

Tools and Technologies:

• Proficiency with SCADA systems and PLC programming platforms (e.g., Siemens TIA Portal, Rockwell Studio 5000).
• Familiarity with MES and manufacturing scheduling software.
• Experience with data collection and analysis tools (e.g., Excel, SQL).
• Knowledge of process optimization tools (e.g., Lean Manufacturing, Six Sigma).

Other Requirements:

• Ability to work in a fast-paced, dynamic manufacturing environment.
• Strong leadership skills and the ability to collaborate effectively with teams at all levels.
• A commitment to maintaining safety, quality, and operational excellence in all tasks.
• Willingness to travel as necessary for site visits, system upgrades, or troubleshooting.