Senior Controls Engineer
Responsibilities:
The Senior Controls Engineer will provide technical leadership in evaluating and implementing automation and controls improvements to enhance manufacturing efficiency, quality, compliance, and safety. This role involves assessing existing process controls, identifying areas for improvement, and working closely with maintenance teams. Additionally, the position will provide technical support for large-scale projects, including automation design, implementation, and validation. A key responsibility is to support and sustain production through adherence to design control processes, engineering best practices, and proper documentation.
Essential Duties & Responsibilities:
- Serve as a subject matter expert (SME) for assigned equipment and machine control systems, leading troubleshooting and problem-solving efforts.
- Conduct independent analysis and develop solutions to complex problems, identifying opportunities for process, machine control, and network/server improvements while optimizing costs.
- Create and update P&IDs, wiring schematics, and I/O drawings for control systems.
- Oversee project scope, design, FAT, SAT, start-up, commissioning, and support validation for equipment and control systems.
- Provide engineering, controls design, and programming support, including development, modification, and troubleshooting of AC/DC Drives, PLCs, HMIs, SCADA, Vision Systems, and Robot Controllers.
- Initiate and manage projects in accordance with program management guidelines.
- Contribute technical input to long-term replacement planning, short-term continuous improvement initiatives, and system lifecycle management strategies.
- Apply root cause analysis methodologies to identify and implement robust technical solutions.
- Enhance manufacturing system performance, focusing on OEE improvements (quality, performance, and uptime), maintenance efficiencies, material usage variance (MUV), and scrap reduction.
- Work on diverse and complex problems requiring data analysis and evaluation.
- Operate with a high degree of autonomy while seeking input from senior engineers as needed.
- Collaborate with Quality Engineers on qualification activities for new or modified processes and equipment.
- Ensure compliance with current Good Manufacturing Practices (cGMP) in all areas.
- Provide training to new employees on HMIs, equipment usage, system documentation, and department procedures.
- Offer input on performance evaluations for project-related activities.
- Communicate effectively with managers, peers, and cross-functional teams to drive collaboration and ensure clarity.
- Address conflicts and disagreements constructively, working towards consensus and resolution.
- Participate in special projects as required.
Requirements:
- Strong understanding of automation, plastic injection molding, part assembly, fixturing, testing, and process control techniques.
- Advanced competency in automation and controls, with familiarity in related domains within the team.
- Ability to make independent decisions impacting project objectives and overall success.
- Proficiency in programming languages and platforms such as Rockwell, FactoryTalk, and Allen-Bradley.
- Solid understanding of equipment strategy with the ability to recommend solutions for critical issues.
- Bachelor's degree in electrical engineering (or a related field) required.
- Minimum of 4 years of relevant experience.
- Work is primarily performed in a professional office and cleanroom environment, with occasional lifting of objects up to 25 lbs.
- Typically requires on-site work, with occasional travel (less than 5%).
