The Automation and Controls Engineer reports to the Manager of Manufacturing Engineering and is responsible for developing new automation concepts and maintaining existing automated manufacturing systems. The Automation and Controls Engineer will identify opportunities to optimize safety and quality while maximizing the efficiency of automated manufacturing systems.
This position will support Production, Maintenance, and Process Teams in troubleshooting equipment across multiple facilities. Duties also include programming, upgrading, and troubleshooting PLCs, Human Machine Interfaces, vision, and data acquisition systems on new and existing production equipment. The role provides technical training and support to maintenance, manufacturing, and engineering personnel in the operation and maintenance of automated equipment.
Roles and Responsibilities:
- Automate all applicable manufacturing processes with ROI justification.
- Identify, develop, and lead projects that will result in automated operations in Manufacturing and Packaging operations.
- Identify, select, and manage the purchasing of components to build automated systems, as well as the vendors who install and support such systems.
- Troubleshoot and eliminate control systems issues and handle controls projects.
- Develop and document new PLC control systems from concept to qualification.
- Troubleshoot control systems wiring and PLC/SCADA logic.
- Maintain configuration control of current PLC source code.
- Select, test, and integrate hardware and software components such as robots, analog devices, motion controllers, sensors, vision systems, and lasers.
- Troubleshoot problems with on-line vision inspection systems utilizing Cognex InSight software and other vision software tools
- Implement quality improvement projects through error-proofing, interlocks, and vision system (Cognex Vision) integration.
- Lay out new industrial electrical control panels which are NFPA79/NEC/UL508A/CE compliant and create electrical and pneumatic schematics.
- Manage electrical cabinet builds, field wiring, and pneumatic plumbing.
- Arrange for and manage appropriate third-party contractor support for services associated with the electrical operations of production equipment and facilities.
- Understand process control issues and develop control solutions to enhance processes with Process/Manufacturing Engineers.
- Collaborate with members of the engineering department and other groups to continuously improve methods of integrating controls technology, with goals being enhanced safety, enhanced functionality, and reduced cost.
- Provide controls engineering support to plant operations and maintenance department.
- Maintain regular attendance.
- Communicate effectively with other departments within the organization and function within a team environment.
- Perform other duties as required in meeting company objectives.
Minimum Requirements:
- Robotics and Automation Engineering experience is essential.
- Strong electrical troubleshooting and PLC programming and troubleshooting is required.
- Supervisory experience is preferred.
- Strong mechanical aptitude and a working knowledge of electrical and mechanical systems are required.
- Excellent troubleshooting and diagnostic skills, with the ability to define problems and resolve them quickly.
- Good interpersonal skills required, with the ability to interact with all staff levels.
Education and Experience:
- Bachelor's degree in Engineering, preferably Electrical, Chemical, or Mechanical.
- Minimum of 2-4 years' experience as an Automation/Controls Engineer in a regulated industry.
- Experience in a cGMP facility is preferred.
- Strong problem-solving and applied statistics skills are required.
- Technical expertise and application experience in manufacturing-based applications.
- Experience in root cause analysis techniques and failure mode and effect analysis.
- Certification in Lean manufacturing is preferred.
- Six Sigma certification (green/black belt) is preferred.
- Experience in CAD/SPC/Gantt Charts.
- ERP experience is a plus, preferably design, testing, and implementation related to manufacturing processes.
- Self-motivated worker with the ability to identify priorities and work independently.
Supervisory Responsibilities:
- Ability to lead internal employee groups as well as contracted vendors in support of automation/controls/robotics projects.