Controls & Automation Engineer

Controls & Automation Project Engineer

The Controls & Automation Project Engineer is responsible for the design, implementation, commissioning, and continuous improvement of automation, controls, and digital manufacturing systems. This role leads capital projects and technical initiatives that improve safety, reliability, quality, productivity, and operating costs across manufacturing operations.

The engineer serves as the technical lead for PLC, HMI, SCADA, industrial network, instrumentation, robotics, and digital factory systems while partnering closely with Operations, Maintenance, Quality, Supply Chain, and external vendors to deliver projects on time and within budget. This role aligns with industry best practices for automation, cyber security, process control, and project management.

Key Responsibilities:

• Automation & Controls Leadership
• Design, program, troubleshoot, and optimize PLC, HMI, SCADA, VFD, servo, and motion control systems.
• Develop automation standards and control philosophies for manufacturing processes.
• Lead commissioning, startup, FAT, SAT, IQ/OQ, and validation activities for new equipment and systems.
• Support factory automation infrastructure including industrial networking, remote access, and control system architecture.
• Improve process performance through advanced controls and automation technologies.
• Capital Project Management
• Manage automation and controls projects from concept through startup and handover.
• Develop equipment specifications, URS documents, project scopes, and technical standards.
• Create project schedules, budgets, and resource plans.
• Coordinate contractors, system integrators, OEMs, and internal stakeholders.
• Deliver projects safely, OTIF (On Time In Full), and within approved budgets.
• Process Improvement & Reliability
• Identify opportunities to improve OEE, waste, throughput, energy consumption, and labor efficiency through automation.
• Drive root cause analysis and corrective actions for major equipment failures.
• Optimize machine performance using data analytics and process monitoring tools.
• Support reliability initiatives and predictive maintenance programs.
• Digital Manufacturing & Industry 4.0
• Support implementation of digital factory technologies and smart manufacturing initiatives.
• Develop dashboards, reporting tools, and automated performance monitoring systems.
• Integrate manufacturing systems with business and enterprise applications.
• Leverage IIoT, data historians, and analytics platforms to improve decision making.
• Cyber Security & Compliance
• Ensure automation systems comply with corporate cyber security standards.
• Support network segmentation, backup strategies, disaster recovery, and system security initiatives.
• Maintain compliance with GMP, Food Safety, OSHA, electrical codes, and site safety standards.
• Participate in risk assessments, machine safety reviews, and process hazard evaluations.
• Technical Leadership
• Provide technical coaching and training to maintenance technicians, engineers, and operations personnel.
• Develop and maintain electrical drawings, software backups, documentation, and control narratives.
• Establish equipment standards and best practices across the facility.
• Act as the site subject matter expert for controls and automation systems.
• Provide technical support as part of C&A team for 24/7 factory operation as required.

Required Qualifications:

• Bachelor's Degree in Electrical Engineering, Controls Engineering, Automation Engineering, Mechatronics, Computer Engineering, or related technical discipline.
• 3 to 7 years of experience in industrial automation, controls engineering, or manufacturing project engineering.
• Experience with food, beverage, consumer goods, pharmaceutical, or related manufacturing environments.
• Demonstrated experience managing automation-related capital projects.

Technical Skills Required:

• PLC Programming (Rockwell, Allen-Bradley, Siemens, or equivalent)
• HMI/SCADA systems
• Industrial networking (Ethernet/IP, Profinet, Modbus)
• Instrumentation and process control
• Electrical troubleshooting
• VFDs, motor controls, and MCC systems
• Project management and contractor coordination

Preferred:

• FactoryTalk View
• FactoryTalk Batch
• FactoryTalk AssetCentre
• OSI PI
• Robotics and vision inspection systems
• SQL databases and reporting tools
• Power BI, PowerApps, or automation dashboard development
• ISA, PMP, TÜV, or related certifications

Key Competencies:

• Safety Leadership
• Project Management
• Technical Problem Solving
• Data-Driven Decision Making
• Continuous Improvement
• Cross-Functional Collaboration
• Communication & Influence
• Change Management
• Digital & Automation Innovation

Success Measures:

• Safety performance and compliance
• OTIF capital project delivery
• OEE improvement
• Downtime reduction
• Waste reduction
• Automation system reliability
• Cyber security compliance
• Cost savings delivered
• Training and capability development of site personnel
• Successful deployment of digital manufacturing technologies