Sr Controls Engineer

EnerSys is the global leader in stored energy solutions for industrial applications. We have over thirty manufacturing and assembly plants worldwide servicing over 10,000 customers in more than 100 countries. Worldwide headquarters are located in Reading, PA, USA with regional headquarters in Europe and Asia. We complement our extensive line of Motive Power and Energy Systems with a full range of integrated services and systems. With sales and service locations throughout the world, and over 100 years of battery experience, EnerSys is the power/full solution for stored DC power products. 

 

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, includes generation of justification, total cost, project schedule and ROI.
2. Ability to keep controls engineering team on task and projects completed on time. This includes ensuring the 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, 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 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 relevant engineering discipline. Electrical or Electronic Systems Engineer preferred. 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 required. Can substitute 10 years’ experience in other automated manufacturing.

2. Knowledge of control wiring and safety circuit design with ability to design these systems from scratch.

3. Knowledge of Fanuc robot programming including IR vision training. Motoman robot experience is also a plus.

4. Knowledge of PLC, HMI, and ethernet based I/O devices. Ability to write complex PLC programs from scratch.

5. Communications skills, both verbal and written.  Effective in influential and instructional communications within various levels of the organization, and to outside agencies and contractors. 

6. Computer skills including word processing, spreadsheets, and databases and an understanding of computer systems and software applications, including design software, programmable control systems and Microsoft Office suite.

7. Knowledge of manufacturing workflow, including planning activities. Complete knowledge of products and their applicat