Senior Manufacturing Controls Engineer - Denver - Brightpath Associates LLC

Description

Job Description

Summary Of Job Responsibilities A Senior Manufacturing Controls Engineer is responsible for designing, implementing, and optimizing manufacturing processes to enhance efficiency, reduce waste, and ensure high-quality production. This position implements corrective actions to resolve manufacturing process problems through testing, evaluation, and analysis.

REPORTING TO : Manager, Manufacturing Engineering

Duties And Responsibilities

• Design and develop control systems for manufacturing equipment and processes.
• Identify and implement corrective actions to resolve manufacturing process problems through testing, evaluation, and analysis.
• Implement automation solutions to improve production efficiency and reduce costs.
• Troubleshoot and correct electrical, instrumentation, and process problems associated with production equipment. PLC, HMI, and other control devices, emphasis on PLC controlled servo/stepper motors and sensor technologies.
• Develop and document functional specifications for production systems including the interface between hardware and software.
• Develop factory-wide sustainable standards for automation controls, hardware, software PLC&HMI, and process monitoring.
• Work with cross-functional teams to ensure product designs are optimized for manufacturability and scalability.
• Partner with maintenance, manufacturing engineering, operations, and quality engineering to implement process improvements, i.e. PLC & HMI program changes.
• Partner with maintenance and operations to solve equipment availability (downtime) related to motor driven control elements.
• Create electrical schematics and oversee the build of new industrial electrical control panels, which are NFPA79/NEC/UL508A compliant.
• Participate in projects involving equipment upgrades, new installations, and process optimization. SNew Equipment Process (NEP) projects to replace, improve, and/or start manufacturing processes.
• Provide technical guidance, support, and training to the manufacturing team and operations team.
• Actively model values: Team, Trust, and Excellence.
• Performs other related duties as assigned.

Knowledge, Skills, And Abilities The requirements listed below are representative of the knowledge, skills, and abilities required to perform this job successfully.

• Proficiency in PLC programming (e.g., Allen-Bradley, Siemens), SCADA systems, and industrial networking.
• Proficient in Programmable Logic Controllers (PLCs) programming (Rockwell/ Allen Bradley).
• Proficient in HMI program development, to include a wide range of controller generations from SLC500 to ControlLogix.
• Demonstrated ability to develop Human-Machine Interfaces (HMIs) to facilitate interaction between operators and machinery.
• Knowledge of industry standards and regulations to ensure compliance and maintain safety in control systems.
• Knowledge of servo / stepper motor theory of operations and condition monitoring techniques.
• Demonstrated ability to program and implement a variety of machine sensors (Cognex machine vision, digital, and analog devices).
• Working knowledge of industrial robots and ability to develop repeatable program architecture.
• Knowledge of current standards and codes as related to machine safety and fail-safe design (ISO, NFPA, NEMA, NEC, ANSI).
• Demonstrated ability to connect a variety of plant and machine systems through the required communication protocols (Serial, OPC, FTP).
• Demonstrated experience in Electrical AutoCad / Solidworks. Must be able to design control circuits, overload protection, create and edit machine electrical drawings.
• Demonstrated experience in data analysis using basic statistical comparison techniques & Statistical Process Control (SPC).
• Experience with Lean Manufacturing, Six Sigma, or similar methodologies is a plus.
• Excellent communication skills, both written and verbal.
• Demonstrated experience working collaboratively with key stakeholders.

Education And Experience

• Bachelor's degree in Electrical Engineering, Controls Engineering, or related field, required.
• 5+ years of experience with controls, automation, electrical design, troubleshooting, and machine commissioning.
• Experience with Rockwell PLCs / HMI, required.
• Systems integration experience, i.e. integration of various servo, sensor and vision technologies through PLC and HMI, required.

Key Competencies To perform the job successfully, an individual should demonstrate the following competencies:

• Safety and Security: The individual actively promotes and personally observes all safety procedures. The individual complies with Environmental, Safety, and Hazardous Communications requirements.
• Operational Excellence: The individual is dedicated to providing organizational systems for measuring work. The individual seeks to reduce variances in organizational processes.
• Interpersonal Skills: The individual remains open to other ideas and exhibits a willingness to try new things.
• Relationships with Others: The individual works effectively with others, including superiors and colleagues. The employee exhibits a professional manner in dealing with others and works to maintain constructive working relationships.
• Problem Solving: The individual participates in the continuous improvement process by attending meetings and presenting problems and possible solutions to the appropriate personnel.
• Communication and Contact: The individual communicates effectively both verbally and written with superiors, colleagues, and individuals inside and outside the Company.
• Planning/Organizing: The individual prioritizes and plans work activities, uses time efficiently, and develops realistic action plans.
• Quality Control: The individual demonstrates accuracy, thoroughness, and monitors their own work to ensure quality. The individual delivers the highest quality products that meet the requirements of internal and external customers.
• Adaptability: The individual adapts to changes in the work environment, manages competing demands and is able to deal with frequent change, delays, or unexpected events.
• Dependability: The individual is consistently at work and on time, follows instructions, responds to management direction, and solicits feedback to improve performance. The individual completes all duties as assigned, trains as required, and rotates into other departments as required.

Notes

Experience with Rockwell PLCs / HMI, required.