Job Title: Production Control Systems Engineer

Job Summary:

The Senior Production Control Systems Engineer is responsible for leading the design, integration, optimization, and management of advanced production control systems in a manufacturing environment. This role involves overseeing the configuration and performance of SCADA, PLC, and Manufacturing Execution Systems (MES) to ensure production processes run smoothly, efficiently, and in compliance with quality standards. The Senior Engineer will take a leadership role in troubleshooting complex system issues, mentoring junior engineers, driving continuous improvement initiatives, and collaborating with senior leadership to ensure that production control systems align with the company's strategic objectives.

Key Responsibilities:

1. Leadership in Production Control Systems Strategy:

   • Lead the development and implementation of the strategy for production control systems, including SCADA, PLC, and MES, to ensure they meet production goals and align with company objectives.
   • Oversee the integration of automation systems with production processes, ensuring efficiency, scalability, and high reliability.
   • Make strategic decisions on the selection and deployment of new control technologies to optimize system performance.

2. SCADA and PLC Programming and Optimization:

   • Design, develop, and optimize complex PLC programs and SCADA configurations to improve automation, data collection, and real-time control of production processes.
   • Lead troubleshooting efforts for complex issues in production control systems, resolving any system failures or performance issues to minimize downtime.
   • Ensure the control systems are configured to improve production efficiency, quality, and throughput while adhering to safety standards.

3. Project Leadership and Execution:

   • Lead large-scale production control system projects, from planning through execution, ensuring all phases of the project are completed on time, within budget, and to the required quality standards.
   • Collaborate with other departments (e.g., operations, quality, maintenance, and IT) to ensure the successful implementation and integration of new control systems or upgrades.
   • Manage project timelines, resource allocation, risk assessment, and vendor relationships to ensure successful project delivery.

4. Operational Efficiency and Continuous Improvement:

   • Identify opportunities to optimize production workflows by analyzing data from SCADA, PLC, and MES systems to identify inefficiencies, bottlenecks, and areas for improvement.
   • Implement and drive continuous improvement initiatives using Lean Manufacturing, Six Sigma, and other process optimization methodologies to reduce waste and increase operational efficiency.
   • Lead efforts to enhance the reliability, flexibility, and scalability of control systems to accommodate changes in production requirements.

5. Team Leadership and Mentorship:

   • Mentor and lead a team of engineers, providing guidance and technical expertise to junior and mid-level engineers to support their growth and development.
   • Foster a culture of knowledge-sharing and collaboration within the engineering team, encouraging the adoption of best practices and innovative solutions.
   • Conduct performance reviews and provide feedback to ensure that team members are developing their technical skills and meeting project expectations.

6. Quality Assurance and Compliance:

   • Ensure that all production control systems meet industry standards, regulatory requirements, and internal quality standards.
   • Collaborate with quality assurance teams to develop and implement quality control procedures, ensuring that production systems maintain high-quality outputs.
   • Oversee system audits, compliance checks, and performance evaluations to ensure that the control systems remain in full compliance with operational standards.

7. Collaboration with Senior Leadership:

   • Act as the key technical liaison between the engineering team and senior management, ensuring that production control systems align with strategic business goals.
   • Provide technical expertise and insights to senior leadership to guide decision-making related to process improvements, system upgrades, and capital investments.
   • Report on the performance, ROI, and benefits of automation and production control systems to the executive team.

8. Risk Management and Troubleshooting:

   • Lead efforts to identify and mitigate risks associated with production control systems, including system failures, downtime, and operational bottlenecks.
   • Oversee root cause analysis and corrective actions to resolve complex issues affecting system performance and production schedules.
   • Develop contingency plans and ensure system redundancy and failover mechanisms are in place to maintain continuous production in the event of a system failure.

9. Documentation and Reporting:

   • Ensure comprehensive documentation of system configurations, programming, maintenance, and troubleshooting activities to maintain clear records for compliance and future reference.
   • Prepare detailed technical reports and presentations for senior management, outlining system performance, project progress, and key performance indicators (KPIs).
   • Maintain clear and up-to-date records of system changes, maintenance schedules, and compliance audits.

10. Technology Adoption and Innovation:

    • Stay abreast of emerging trends and advancements in automation, production control systems, and industry technologies.
    • Evaluate and recommend new technologies and tools that could enhance automation capabilities, improve production control, and reduce costs.
    • Lead the adoption and integration of innovative technologies that contribute to the long-term success and growth of manufacturing operations.

Key Focus Areas:

• Strategic Control Systems Leadership: Guide the strategic direction for SCADA, PLC, and MES systems, ensuring alignment with organizational goals and production efficiency.
• Advanced Programming and Troubleshooting: Lead the optimization of production control systems, resolving complex technical issues and improving system performance.
• Operational Excellence: Identify and implement continuous improvements in production processes through data-driven insights, Lean Manufacturing, and Six Sigma methodologies.
• Team Leadership and Mentorship: Provide leadership and technical guidance to the engineering team, driving professional development and ensuring high performance.
• Collaboration and Stakeholder Engagement: Work closely with senior leadership and other departments to ensure that production control systems align with the company's broader business objectives.

Skills and Knowledge Required:

• Expert-level knowledge of SCADA systems, PLC programming (e.g., Siemens, Allen-Bradley, Rockwell Automation), and MES.
• In-depth understanding of automated manufacturing processes, production control, and manufacturing execution systems.
• Proven ability to troubleshoot, optimize, and program complex control systems to meet operational requirements.
• Strong project management skills, including experience managing large-scale system upgrades and implementing process improvements.
• Deep experience with Lean Manufacturing, Six Sigma, and other continuous improvement methodologies to optimize production processes.
• Excellent leadership, mentorship, and team management skills, with the ability to guide engineers and collaborate effectively across departments.
• Strong communication skills to effectively interact with senior management and provide clear technical insights.
• Ability to think strategically and translate business goals into technical solutions.

Educational Qualifications:

• Bachelor’s or Master’s degree in Industrial Engineering, Automation Engineering, Electrical Engineering, Mechatronics, or a related technical field.
• Relevant certifications in project management (e.g., PMP), PLC programming, SCADA systems, or industrial automation (e.g., Six Sigma, Lean Manufacturing) are highly desirable.

Experience:

• 7+ years of experience in industrial automation, production control, or instrumentation engineering, with at least 3-5 years in a senior or leadership role.
• Proven track record of leading and delivering complex automation projects in manufacturing environments.
• Extensive experience with SCADA systems, PLC/SCADA programming, MES, and automated manufacturing equipment.
• Experience managing cross-functional teams, collaborating with senior leadership, and driving business initiatives through technological solutions.

Tools and Technologies:

• Proficiency with SCADA systems and PLC programming platforms (e.g., Siemens TIA Portal, Rockwell Studio 5000, Wonderware).
• Experience with industrial automation tools, robotics, and MES.
• Familiarity with data collection and analysis software (e.g., Excel, SQL, or similar data visualization tools).
• Knowledge of process optimization tools and software.

Other Requirements:

• Strong leadership and decision-making capabilities to drive projects and manage teams effectively.
• Ability to manage multiple projects simultaneously, balancing strategic and technical priorities.
• A deep commitment to safety, quality, and operational excellence in all tasks and initiatives.
• Willingness to travel as necessary to support system implementation, troubleshooting, and cross-site collaboration.