The Mid-Sr. Level Process Control Engineer is customer-facing and is engaged in a variety of activities across multiple industries. The engineer will be expected to be an excellent representative of the company while implementing automated programming and processes that will drive the successful execution of various projects at customer sites.
The Process Control Engineer is responsible for working with outside customers and vendors to define, develop, engineer, and implement projects and scopes of work established in alignment with project goals and objectives. He/she will be focused and possess a high level of technical accuracy and a deep understanding of process knowledge. He/she must have the ability to collaborate with a team that will implement and maintain process controls in a safe, reliable, and economical operation. A successful candidate will be expected to assimilate quickly and begin delivering results in an expedient manner. He/she will also develop an awareness of operational history recognizing the value of information sharing and knowledge transfer.
This position will be based out of Wilmington, NC.
Skills & Qualifications:
Support existing control systems utilized in manufacturing operations
Participate in long-term strategic development of site process control systems.
Provide controls/automation technical support for troubleshooting and problem-solving of manufacturing operations control systems/automation/instrumentation issues. This will include new installations, as well as replacement or upgrading of existing systems.
The position will require working closely with Facilities and Manufacturing personnel to ensure process / product quality through function of manufacturing control systems.
This position will require working with validated and non-validated systems. Modifications to validated system will require working within the Change Control program.
This position will also require the development and implementation of system commissioning plans and interact with Validation on the qualification of these systems.
Troubleshooting and problem-solving of existing manufacturing operations control systems/automation/instrumentation issues.
Provide 24/7 support to Manufacturing on a rotation based schedule.
Diagnose technical issues and provide recommendations/solutions for corrective actions.
Follow established Quality Control systems.
Create or review changes and assure appropriate design documentation (User Requirements, Functional Specifications, Software Design Specifications, Software Test Plans, IQ/OQ) are developed and on file.
Execute control systems projects/assignments in the support of site operations through investigations, control system assessments, and design support. Proactively look for and recommend improvements in site processes and procedures.
Review, specify, design and/or install process control systems in direct support of commercial and clinical manufacturing operations.
Provide direction to junior engineers
Support and/or execute acceptance testing and IOQ protocols.
Maintain a library for vendor application software, historical data storage, back-up custom software applications, and required hardware needed for troubleshooting and maintenance.
Maintain support for plant automation, including the design, implementation, and documentation of system changes.
Interface with QA Validation group for GMP systems
Extensive experience in PLC and data acquisition systems, distributed control systems (DCS), mechanical operation of equipment, and process control are essential.
Experience with developing GAMP controls documentation for internal projects as well as reviewing/approving vendor supplied documentation (User Requirements, Functional Specifications, Software Design Specifications, and Software Test Plans).
Allen-Bradley PLC hardware and software experience required (SLC, CompactLogix, ControlLogix, RSLogix500, RSLogix5000, and DeviceNet).
S-88 Batch programming experience required
Experience with networks and communication protocols preferred.
GE Proficy iFix SCADA experience preferred.
iBatch, Rockwell Batch or DeltaV Batch experience preferred.
Virtual Machines experience preferred.
DeltaV Live or Operate experience preferred
OSIsoft PI Historian experience preferred.
Johnson Controls Metasys Building Monitoring System (BMS) experience preferred.
Minimum of 10 years of experience with the installation, startup, and servicing of process control systems. GMP experience preferred.
Prior experience supporting manufacturing utility systems strongly preferred (WFI, RODI, waste neutralization, chilled water, heating hot water, steam)
Minimum of 5 years of experience in pharmaceutical environment including regulatory requirements associated with 21 CFR Part 11 and supporting validation of control system equipment.
Prior experience with controls systems supplied with skidded equipment utilized in fermentation, cell separation and recovery, filtration, CIP, and clean utilities preferred.
BS or MS Chemical, Electrical, or Mechanical Engineering from an accredited university
Provide technical sales support for Company sale team members
Travel to client facilities for technical sales support, project review and implementation as required
Perform project related engineering services, including:
Control System design & programming
System and Functional documentation
Startup and Commissioning
Perform programming on both PLC and DCS based control platforms, including but not limited to ABB System 800xA, Rockwell ControlLogix / PlantPAx platforms, and Emerson DeltaV
Provide technical and maintenance support to existing control system platforms at Company client facilities.
Perform managerial duties, including:
Resource Time & Expense approval
Resource task assignment and management
Support executive team members in setting up policies, procedures, and protocols as we continue our diversification into other industries and overall company growth
Must have strong communication skills.
Must have project management and leadership experience
Qualified candidates must have a minimum of 7 to 10 years of hands-on experience with Rockwell ControlLogix, PlantPAx, ABB System 800xA, or current Distributed Control Systems.
Experience in the coordination and implementation of DCS/PLC upgrades and/or new installation/startup
Experience with instrumentation, motor control, regulatory control loop tuning, and advance control processes.
Experience with loop performance evaluation tools and process data historians (i.e. PI) is a plus
The Process Control Engineer/Automation Lead will:
· Provide technical sales support for Company sale team members
· Travel to client facilities for technical sales support, project review and implementation as required
· Perform project related engineering services, including:
o Project management
o Project estimation
o Control System design & programming
o System and Functional documentation
o Startup and Commissioning
· Perform programming on both PLC and DCS based control platforms, including but not limited to ABB System 800xA, Rockwell ControlLogix / PlantPAx platforms, and Emerson DeltaV
· Provide technical and maintenance support to existing control system platforms at Company client facilities.
· Perform managerial duties, including:
o Resource Time & Expense approval
o Resource scheduling
o Resource task assignment and management
· Support executive team members in setting up policies, procedures, and protocols as we continue our diversification into other industries and overall company growth
· Strong communication skills
· Project management and leadership experience
· Qualified candidates must have a minimum of 7 to 10 years of hands-on experience with Rockwell ControlLogix, PlantPAx, ABB System 800xA, or current Distributed Control Systems.
· Experience in the coordination and implementation of DCS/PLC upgrades and/or new installation/startup
· Experience with instrumentation, motor control, regulatory control loop tuning, and advance control processes.
· Experience with loop performance evaluation tools and process data historians (i.e. PI) is a plus
You will be responsible for designing, developing, installing, and maintaining equipment which is used to power, monitor, and control industrial systems, machinery, and processes. You will further be responsible for all equipment specification, layout design, quality, efficiency, and providing instruction and technical support to manufacturing plants. To qualify for this position, you must have 5+ years of controls engineering experience in an industrial, discrete manufacturing environment. The position requires up to 66% travel.
To perform well in this role, you will need to:
Provide technical support for all controls, measuring devices, and test equipment
Provide support for special projects including, but not limited to, component selection, controls recommendations, vendor recommendations, and installation
Oversee project workflow and supports internal and external resources to ensure timely delivery of projects while meeting performance and budget targets
Direct, test and diagnose malfunctioning apparatus such as Programmable Logic Control Programs, drives, motors
Consult with equipment suppliers to determine appropriate equipment, specifications, and maintenance protocols
Provide technical support to Maintenance Departments on all electrical/electronic matters
Create and maintains electrical drawings and schematics
Write and/or modifies PLC programs as equipment changes warrant
Conduct research and development investigations to develop and test new equipment, processes, and procedures
Assure each plant has the proper documentation and labeling to assure compliance with arc flash safety requirements
Perform regular arc flash studies of each facility to maintain compliance with federal, state, and local regulations
Perform regular analysis of electrical components to improve system reliability and reduce risks associated with improperly connected or overloaded circuits and devices
Recommend and implement proper and timely predictive/preventive maintenance on all electrical equipment
Qualifications to be considered for the role:
· We require extensive professional, technical, or administration training. Bachelor’s degree or higher in Electrical or Electronic Engineering from an ABET accredited institution; broad knowledge of a technical field applicable to Electronics Technology , Electrical/Electronic Engineering or Industrial Electronics including a working knowledge of Computer Aided Design (CAD), AC and DC drives, PLC Control Logic
· Computer skills including Microsoft Windows; Microsoft Office and Autocad.
· We require someone with a minimum of 5 years’ work-related experience in an industrial manufacturing environment. A strong background in troubleshooting foreign (Italian/German) production machinery and schematics is preferred.
· Organizational experience with CMMS (Computerized Maintenance Management Software) preferred.
· Should have significant experience in the following: A proven track record of success in a manufacturing Electrical Engineering or Process Controls role, stable work history, knowledge of Lean Manufacturing Practices, and the ability to lead and oversee the electrical and process controls functions of a multi-facility environment.
Newly created, hands-on PM role will oversee all aspects of projects, including control system integration, engineering, contractors, and procurement.
Responsible for managing multiple projects at a time from small to extremely complex as well as facilitating proposal development and customer relationships.
This is a leadership role that requires strong technical ability, communication skills, the ability to mentor others and establish relationships with clients and vendors.
The candidate must have the ability to conceptualize, detail and implement control systems for various processes and discrete automation projects while managing scope, schedule and budget effectively.
Ideal candidate will be comfortable working in the field as necessary to review and verify instrumentation, control hardware, networks, and electrical work to ensure quality deliverables are provided to the customer.
The ideal candidate must have a diverse engineering and technical skill set with the ability to work independently. This person will act as technical lead on projects and mentor junior engineers and technicians.
Experience – Greater than 10 years with capabilities in below areas is preferred:
o Experience in one or more of the following industries: Oil & Gas, Water/Wastewater, Mining Life Sciences, Building Automation, Manufacturing and Food & Beverage.
o Experience in the design of electrical schematics, including power distribution under 480VAC, control panels and associated NEC references desired.
o Experience with programming and implementation of RTUs, PLCs, DCS, SCADA and Industrial networks strongly preferred.
o Experience leading a team of engineers/technicians to provide control system solutions
o Experience mentoring less experienced engineers
Travel: Estimated 25%- 50% domestic.
Education – BS in Electrical/Control Engineering, Mechanical Engineering, Chemical Engineering, or Computer Science is strongly desired.
Preferred Qualifications and Skills:
o Relevant Certifications: PMP, Scrum, ADKAR, Lean, Six Sigma, CAP
o Ability to prioritize multiple projects and competing priorities
o Results oriented and self-motivated
o Proven experience in architecting, managing and executing large, complex projects
o Ability to manage multiple projects with multiple teams across the nation simultaneously
The Packaging Automation Engineer is responsible for complete project execution including system automation design, testing, documentation management, installation and start-up.
Education/Experience: BS in Engineering or equivalent technical degree plus 5 or more years of project or packaging automation in the Food and Beverage, Consumer Products, or Pharmaceutical Industry desired.
Travel: Project Dependent up to 25%
The successful candidate will be responsible for specifying, implementing, maintaining, and updating plant process control systems to ensure optimum efficiency, availability, and safety.
Required Education/Qualifications/Work Experience:
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