Process Controls Engineer

Job Description

Process Controls Engineer

Position Overview

We are seeking a hands-on Process Controls Engineer to support automation, instrumentation, and control systems within a manufacturing environment. This role is responsible for maintaining and optimizing production equipment, supporting day-to-day operations, and participating in the design, implementation, and commissioning of new automation systems and process improvements.

The ideal candidate will work closely with Engineering, Operations, Maintenance, and R&D teams to improve safety, reliability, efficiency, and overall process performance through effective automation and data-driven decision making.

Key Responsibilities

• Maintain, troubleshoot, and optimize PLC, HMI, and SCADA systems supporting manufacturing operations.
• Develop, test, and document PLC programs, control logic, and operator interfaces for both new and existing equipment.
• Diagnose and resolve mechanical, electrical, instrumentation, and controls-related issues to minimize downtime and improve equipment reliability.
• Partner with maintenance and operations teams to implement repairs, upgrades, and process improvements with minimal impact to production.
• Create, update, and maintain technical documentation including P&IDs, control narratives, electrical schematics, logic diagrams, network drawings, and equipment documentation.
• Integrate production equipment into facility networks to support remote monitoring, automation, data collection, and process control.
• Manage control system backups, software updates, version control, and change management activities.
• Develop and maintain interfaces that collect operational data from production equipment into databases, historians, and reporting systems.
• Analyze operational and process data to identify opportunities for increased efficiency, improved yields, greater throughput, and enhanced process stability.
• Support commissioning, startup, validation, and optimization of new equipment, automation systems, and process modifications.
• Train operators and maintenance personnel on automation systems, troubleshooting procedures, and best practices.
• Collaborate with third-party contractors, control system integrators, and equipment vendors on automation-related projects.
• Evaluate and recommend emerging automation technologies that improve manufacturing performance.
• Participate in root cause investigations, safety initiatives, and continuous improvement activities.
• Assist in developing and maintaining automation standards, operating procedures, and best practices.

Qualifications

• Bachelor's degree in Electrical Engineering, Controls Engineering, Automation Engineering, Chemical Engineering, Mechanical Engineering, or a related technical discipline.
• Experience supporting manufacturing equipment, automation systems, process controls, or industrial instrumentation in a production environment.
• Working knowledge of:
• PLC programming and troubleshooting
• HMI and SCADA systems
• Industrial instrumentation and process controls
• Electrical control systems and industrial networking
• Ability to read and interpret:
• P&IDs
• Electrical schematics
• Control narratives
• Logic diagrams
• Network drawings
• Strong troubleshooting and problem-solving skills in industrial environments.
• Excellent communication and teamwork skills with the ability to partner effectively across multiple functions.

Preferred Qualifications

• Experience in process manufacturing industries such as biotechnology, fermentation, food processing, pharmaceuticals, specialty chemicals, or related industries.
• Hands-on experience with Allen-Bradley, Siemens, ABB, or similar PLC platforms.
• Experience with HMI and SCADA software such as FactoryTalk, AVEVA InTouch, Wonderware, Ignition, or comparable systems.
• Knowledge of industrial communication protocols including Ethernet/IP, Modbus, Profibus, and related technologies.
• Familiarity with operational technology (OT) cybersecurity principles and best practices.
• Experience with manufacturing data collection systems, process historians, SQL databases, dashboards, or analytics platforms.
• Experience supporting equipment commissioning, startup, and validation activities.

Technical Skills

• PLC programming, commissioning, troubleshooting, and optimization.
• HMI and SCADA development, alarm management, and operator interface design.
• Industrial instrumentation calibration and troubleshooting.
• Process control strategy development and implementation.
• Root cause analysis and corrective action execution.
• Preventive and predictive maintenance of automation systems.
• Industrial networking and communication protocols.
• Manufacturing data collection, reporting, and process analytics.