Manufacturing Controls Engineer

JOB SUMMARY

The Manufacturing Controls Engineer designs, programs, tests, and maintains the electrical, automation, and control systems -- such as Programmable Logic Controllers (PLCs), Human-Machine Interfaces (HMIs), robotics, and industrial networks -- that run industrial production lines in the Barriers & Surfaces Manufacturing Plants in a safe and efficient manner.

Reporting to the VP of Engineering, will trouble shoot, design and own the solutions and their implementation in support of plant operations.  Works closely and communicates effectively with the operations team to resolve equipment failures while developing process and control improvements.  Ability to operate effectively in an innovative, fast-paced, multidisciplinary team environment.  Responsible for owning solutions and their implementation.  An individual contributor with a developmental path for a future management role.

ESSENTIAL JOB FUNCTIONS

·       Develop, modify, troubleshoot, and maintain PLC programs, including sequencing, interlocks, permissives, alarms, PID control loops, and equipment control logic.

·       Develop and maintain HMI applications, including process graphics, equipment controls, alarm management, trending, setpoint entry, and operator interfaces.

·       Design and configure industrial control panels and electrical cabinets, including component selection, panel layout, power distribution, circuit protection, terminal blocks, relays, power supplies, PLC hardware, and I/O modules.

·       Read, develop, and troubleshoot electrical schematics, wiring diagrams, panel drawings, loop diagrams, and I/O drawings.

·       Perform hands-on electrical installation and troubleshooting, including wire termination, terminal blocks, relays, contactors, circuit breakers, power supplies, PLC I/O, instrumentation, and control wiring.

·       Configure and troubleshoot digital and analog instrumentation, including 24 VDC discrete signals, 4–20 mA signals, 0–10 V signals, RTDs, thermocouples, and pulse/frequency inputs.

·       Perform PLC I/O checkout, point-to-point verification, loop checks, and functional testing during equipment commissioning and startup.

·       Configure and troubleshoot industrial communication networks and protocols, including EtherNet/IP, Modbus TCP, Modbus RTU/RS-485, serial communications, and Ethernet-based device integration.

·       Integrate PLCs with VFDs, motor starters, instrumentation, mass flow controllers, analyzers, scales, remote I/O, safety devices, and other process equipment.

·       Configure and troubleshoot industrial Ethernet networks, including IP addressing, managed switches, network topology, device communications, and basic network diagnostics.

·       Size and select control-system components, including power supplies, circuit protection, relays, contactors, terminal blocks, PLC modules, communication modules, and control transformers.

·       Troubleshoot control systems from the field device through wiring, I/O hardware, PLC logic, communications, and HMI, identifying root causes of equipment and process-control issues.

·       Support FAT, SAT, commissioning, startup, and field troubleshooting of automated process equipment and control systems.

·       Develop and maintain I/O lists, control narratives, cause-and-effect matrices, alarm lists, network architecture drawings, and control-system documentation.

·       Apply appropriate electrical and controls standards and practices for grounding, shielding, signal segregation, control power distribution, and electrical safety.

·       Other duties as assigned.

·       BS or MS Electrical/Chemical/Mechanical Engineering with Controls/PLC experience or related field

·       Minimum 5 years’ experience in an industrial environment.

·       Interpret mechanical design drawings for electrical requirements.

·       Interpret electrical design, schematics, and drawings.

·       Preferred software experience: Automation Direct, Allen Bradley, Wonderware, and Ignition

·       Strong data analysis capabilities

·       Strong interpersonal and communication skills

·       Skilled use of computers and Microsoft Office applications

·       Ability to work independently and highly self-motivated

·       Travel – up to 40%

The work is performed in an office setting with moderate noise level.  This job frequently requires the employee to stand; walk; sit; use hands; climb stairs; balance; stoop; kneel; read; talk or hear.  The employee must lift and/or move up to 25 pounds.  Specific vision abilities include close vision and the ability to adjust focus.  Reasonable accommodation may be made to enable individuals with disabilities to perform the essential functions.  The employee should never attempt to lift more than 25 pounds.