Process Control Engineer

Process Control Engineer

JOB DESCRIPTION

REPORTS TO: Director of commercialization

DIRECT REPORTS: N/A

JOB TYPE: Full Time

FLSA STATUS: Exempt

ESSENTIAL DUTIES AND RESPONSIBILITIES:

The Process Control Engineer is responsible for installing, modifying, and servicing process control systems throughout Genpak. He/she will work in a high performance, team-centered work environment to support operations and maintenance by driving continuous improvement in the automation and control of the manufacturing processes. Will utilize data management skills, PLC (Programmable Logic Control) skills, Robotic engineering skills and general troubleshooting skills to solve complex manufacturing processes and create enhancements to Genpaks process control systems. Will assist with programming and installing of new equipment during start-up. Duties include:

• Support equipment installation and modification in coordination with Project and Process Engineering initiatives.
• Provide day-to-day support for all software and hardware that comprise the plant control network including PLC's, drives, switches, routers, PC diagnostic and repair, network IP, and industrial communication protocols.
• Work closely with Manufacturing Technicians, Process Engineers, and Robotic Technicians to provide advice and support, help diagnose controls systems and process issues, and lead troubleshooting efforts related to these systems.
• Collaborate with vendors of controls system hardware/software & SCADA software to troubleshoot and enhance the performance of equipment.
• Collaborate with suppliers of related instruments & electronic equipment related to the control equipment. Contact suppliers to clarify performance and application of control equipment, instruments, drives, and other equipment that is part of the control systems.
• Work with SCADA supervisory systems to analyze process data and create process trend graphs.
• Set up, modify, and analyze alarm & event display and archiving.
• Participate in cross-functional continuous improvement teams.
• Lead and execute improvement projects to the automation systems. For larger projects using external resources, function as the Genpak automation liaison.
• Maintain compliance with all plant safety systems and policies, and applicable laws/regulations.
• Utilize lean manufacturing methodologies and problem solving/troubleshooting tools to identify root cause of problem areas in Process Control code, Operator Interface, or hardware and effectively resolve these problems with team member input.
• Specific troubleshooting and optimization activities will include reducing alarms and unplanned events, minimizing elements in manual, tuning controllers, evaluating the impact of automation systems on plant operability issues, participating in Root Cause Investigations, and utilizing tools such as SPC for optimizing plant Process Control systems.
• Travel is required on a regular basis

Note: this description is intended to provide a general overview of the position and is not an exhaustive listing of duties and responsibilities.

• Other responsibilities as assigned.

EDUCATION & EXPERIENCE:

• Associate degree (A.S.) in Electrical Engineering or other related technical field.
• 5 years' experience with PLC programming & software analysis in a manufacturing environment
• In-depth experience installing and supporting industrial control systems and control networks including PLC's, drives, switches, routers, PC diagnostics and repair, network IP, and industrial communication protocols.
• Proficiency with the following control methodologies required: PID loop configuration and analysis; sequential programming; temperature, pressure, and motor speed control.

• Advanced I&E skills -- Capable of using troubleshooting tools and techniques for diagnosing industrial machinery instrumentation. (i.e., Working knowledge of thermocouples, RTDs, pressure and flow transmitters, loops, SCRs and SSRs, encoders, ultrasonic sensors, limit, and proximity sensors. Able to troubleshoot wiring from schematics and P&ID. Able to use multi-meters, amp meters, Fluke calibrator, oscilloscope, pressure calibrator, temperature bath)
• AutoCAD experience is a plus.
• Able to read & edit P&ID drawings.
• Able to write technical communications.
• Able to perform drive configurations and communication protocols associated with drive systems; troubleshoot drive systems.
• Able to work independently under limited supervision and provide direction/leadership to others in automation tasks/projects.
• Strengths in organization and motivation
• Excellent communication, teamwork, and people skills
• Strong analytical skills to analyze process performance and recommend changes.
• Have the ability to work on a high performing team, contributing to an environment where open and honest communication is the norm.
• Ability to build effective workplace relationships, motivating co-workers, and supporting co-worker development.
• Know how to evaluate team effectiveness, and how to improve its performance.
• Must be able to deal with conflict productively, bringing forth issues that need to be discussed and work to forge a mutually beneficial outcome.

Must have the desire to be empowered, work in a collaborative environment, and accomplish more with

Interpersonal/Communication:

• Demonstrate ability to participate and/or foster interdepartmental communication and teamwork.
• Demonstrate ability to prioritize multi-task duties without loss of efficiency or composure.
• Demonstrates effective written and verbal communication and dissemination of information in a diplomatic manner.
• Demonstrates ability to work under pressure, meet scheduled deadlines, meet emergency situations without loss of efficiency or composure.
• Ability to understand, read, write, and speak English as all staff will be required to read and interpret company documents such as safety rules, operating and maintenance instructions, and procedure manuals; required to complete and document all required reports accurately and without assistance; and communicate with supervisors and co-workers regarding daily operations of equipment and material being produced.

Safety:

Demonstrate ability to understand and actively participate in all company safety programs, policies, and procedures.