Process Control Engineer

Job Description

Job Description

Process Controls Engineer

Position Summary

The Process Controls Engineer supports the automation, instrumentation, and control systems used in manufacturing operations, including process production, downstream processing, drying, blending, and packaging activities. This hands-on role ensures that manufacturing equipment operates safely, reliably, and efficiently while supporting the design, implementation, and commissioning of new equipment and process improvements.

The Process Controls Engineer collaborates closely with Engineering, Maintenance, Operations, and Research & Development teams to enhance operational performance through robust automation strategies, process optimization, and data-driven decision-making.

Key Responsibilities

• Maintain, troubleshoot, and optimize PLC, HMI, and SCADA systems supporting manufacturing operations.
• Develop, test, and document PLC control logic and HMI interfaces for both new and existing equipment.
• Diagnose and resolve mechanical, electrical, instrumentation, and controls-related issues to minimize unplanned downtime.
• Partner with maintenance personnel to execute repairs, upgrades, and control system modifications while minimizing production disruptions.
• Create, update, and interpret technical documentation, including P&IDs, control narratives, equipment lists, electrical schematics, network diagrams, and logic diagrams.
• Coordinate with external contractors, system integrators, and vendors as needed to support project execution and specialized technical requirements.
• Integrate standalone equipment into plant and enterprise networks for remote monitoring, data collection, and process control.
• Manage automation software lifecycle activities, including backups, version control, documentation, and change management.
• Develop data collection systems and interfaces to support reporting, analytics, and operational performance monitoring using databases and historian platforms.
• Analyze process data and production trends to identify improvement opportunities and implement control system enhancements that improve safety, quality, yield, throughput, and reliability.
• Support startup, commissioning, qualification, and validation activities for new equipment, automation projects, and process changes.
• Provide technical training and troubleshooting guidance to operations and maintenance personnel on automated systems.
• Evaluate and recommend emerging automation and control technologies for potential implementation.
• Perform additional duties as assigned.

Additional Responsibilities

• Participate in continuous improvement initiatives focused on safety, reliability, operational excellence, and cost reduction.
• Support root cause investigations and corrective action implementation related to process and equipment performance.
• Assist in the development, review, and improvement of standard operating procedures (SOPs), work instructions, and automation best practices.

Work Environment

• Work is performed in a combination of office, laboratory, and manufacturing production environments.
• Frequent interaction with operating equipment and production areas, including exposure to wet, humid, dusty, and noisy conditions.
• Regular collaboration with Operations, Maintenance, Engineering, Quality, and Research & Development teams.
• Occasional after-hours or weekend support may be required during equipment commissioning, troubleshooting, or critical production events.

Minimum Qualifications

• Bachelor's degree in Electrical Engineering, Automation Engineering, Controls Engineering, Mechanical Engineering, Chemical Engineering, or a closely related technical discipline.
• 0-5 years of experience supporting, maintaining, installing, or troubleshooting industrial automation, electrical, mechanical, or control systems in a manufacturing environment.
• Working knowledge of PLCs, HMIs, industrial instrumentation, and automated process controls.
• Basic understanding of industrial electrical systems, control panels, and networking concepts.
• Strong troubleshooting, analytical, and problem-solving skills.
• Ability to work independently as well as within cross-functional teams.

Preferred Qualifications

• Experience supporting manufacturing processes in industries such as biotechnology, pharmaceuticals, food and beverage, specialty chemicals, consumer products, or other regulated manufacturing environments.
• Hands-on experience with PLC platforms such as Allen-Bradley/Rockwell, Siemens, ABB, or similar systems.
• Experience programming and supporting HMI/SCADA platforms such as FactoryTalk, Ignition, AVEVA/Wonderware, WinCC, or equivalent software.
• Familiarity with industrial communications protocols including Ethernet/IP, Modbus, Profibus, Profinet, or similar networks.
• Knowledge of OT cybersecurity concepts and industrial network architecture.
• Experience with data historians, SQL databases, reporting tools, and process performance analytics.

Technical Skills

• PLC programming, troubleshooting, testing, and commissioning.
• HMI and SCADA development, configuration, alarm management, and user interface design.
• Industrial instrumentation calibration, configuration, and troubleshooting.
• Ability to read and interpret P&IDs, electrical schematics, loop drawings, control narratives, and logic diagrams.
• Root cause analysis and implementation of corrective and preventive actions.
• Preventive maintenance planning and reliability improvements for automated systems.
• Understanding of manufacturing data systems, industrial databases, and networking fundamentals.
• Strong documentation and project support skills.