Sr Controls Engineer

Job Purpose

The purpose of this position is to sustain the efficient operation of plant machinery and equipment.  This position also researches, develops, and implements new processes, procedures, and equipment as needed.

Essential Duties and Responsibilities

1. Manage complex projects, including generation of justification, total cost, project schedule and ROI.
2. Ability to keep the Control’s engineering team on task and projects completed on time. This includes ensuring team completes all required safety training, blood draws, hearing tests, and blood lead result signoffs.
3. Attend daily MDI level 5 and 3 meetings in all required areas. Must have good communication skills and able to present 5 Why results in a clear manner.
4. Support the troubleshooting, adjustment, maintenance, and repair of electrical, electronic, and electromechanical automatic and semi-automatic packaging machinery, automation equipment, and systems, including PLC machine controls, servo motor drive systems, robotics, computerized vision systems, AC and DC drives, pneumatic, hydraulic, and other electromechanical equipment.
5. Provide manufacturing decision making information by calculating production, labor, and material costs; including the review of production schedules to estimate future requirements.
6. Generates project plans, performs budget maintenance, and resource coordination for assigned projects.
7. Continual development and implementation of process improvements.  Coordinate machine preventative maintenance.
8. Research, design, procure, implement, test, and monitor new mechanical and/or electronic systems, technologies, and automation equipment.
9. Direct installation, integration, and operational testing of electrical and/or electronic equipment
10. Obtain and maintain operational efficiencies of machinery and equipment.  Set and enforce standard performance specifications on current and new equipment, machinery modifications, and/or procedural changes; monitor performance variances.
11. Manage several projects at one time.

Be compliant in all safety, environment and health processes and procedures.  To include but not limited to wearing required personal protective equipment (PPE), maintaining, and safely storing PPE, and submitting to periodic personal testing and monitoring.

Qualifications

1. BS Degree in controls engineering or relevant engineering discipline.  Electrical or Electronic Systems Engineer preferred. Plus, a minimum of two (2) years of project- based engineering experience. A minimum of five (5) years of project-based engineering experience is considered as relevant work experience, absent a BS degree in engineering.  10 + years in lead acid battery manufacturing preferred. Can substitute 10 years experience in other automated manufacturing.
2. Certified Automation Professional (ISA CAP) is preferred
3. Strong knowledge of control wiring and safety circuit design with ability to design these systems from scratch.
4. Advanced PLC programming and troubleshooting (Allen Bradley & Modicon), Robot programming, logic and troubleshooting (Adept, motorman & Fanuc) including IR vision, Electrical Code.
5. Strong knowledge of PLC, HMI, and ethernet based I/O devices. Ability to write complex PLC programs from scratch or optimize current programs. To include relays, light curtains, interlocks and vision systems.
6. Experience with industrial networking and communication protocols is preferred
7. Exposure to AI/vision-based inspection systems
8. Strong communications skills, both verbal and written.  Effective in influential and instructional communications within various levels of the organization, and to outside agencies and contractors. Including the ability to provide concise and accurat