Process Controls Engineer

Benefits Competitive salary Company paid health and dental benefits Paid vacation and an annual bonus 401K with company match Opportunity for career stability and growth Tuition reimbursement program Protective personal equipment is provided or cost of purchase is reimbursed On the job training Responsibilities & Duties Process improvement: Analyze existing workflows to identify and correct inefficiencies, reduce waste, increase output, and lower production costs. Implement advanced control strategies: Design and program advanced process control (APC) applications, including model predictive control (MPC) and multivariable control systems, to optimize production and improve product consistency. Apply Statistical Process Control (SPC): Utilize SPC techniques to monitor process behavior, identify non-random variations, and trigger corrective actions before defects occur. This includes designing and analysing control charts to maintain statistical control. Provide floor presence and support: Spend significant time on the factory floor to oversee the implementation of control strategies, troubleshoot issues directly with maintenance and operations staff, and ensure automated systems are functioning correctly. Perform validation and documentation: Execute process qualification and continued process verification, developing comprehensive documentation to demonstrate consistent process performance in compliance with regulatory standards (e.g., FDA, ISO). Conduct data-driven analysis: Collect and analyse real-time process data from automated systems to identify trends, deviations, and opportunities for process optimisation. Use data to drive improvement initiatives and root cause analysis. Project Management: Coordinate the full lifecycle of projects, including defining scope, managing timelines, selecting vendors, and commissioning new equipment and control systems. Required Skills & Qualifications Technical expertise: Demonstrated, hands‑on experience with process control methodologies, including advanced control techniques, PID tuning, and SPC. Polymer Science: Understanding of plastic materials (e.g., PP, PE, PET), extrusion, injection moulding, machine set‑up and tool design. Control systems proficiency: Deep knowledge of control systems, instrumentation, and relevant software, such as DCS, PLC, and SCADA systems. Robotics and automation: Proven experience in integrating, programming, and maintaining industrial robotic systems (e.g., FANUC, KUKA) for manufacturing applications. High technical aptitude: A natural inclination for hands‑on problem‑solving, with the ability to quickly grasp and master complex technical systems and diagnostics. Data analysis: Experience with CAD software (SolidWorks, AutoCAD), process simulation, modelling tools (e.g., MATLAB, Simulink), and data analysis software (e.g., Python, Minitab) to drive process improvements. Compliance and documentation: Strong understanding of quality management principles and the ability to produce detailed and accurate validation documentation. Education & Certifications Preferred: Bachelor’s degree in chemical engineering, mechanical engineering, industrial engineering, or related field. Required: 3‑5 years of experience within manufacturing, engineering, or process engineering roles. Strong knowledge of manufacturing processes, equipment, and materials. Proficiency in process simulation, modelling, and statistical analysis tools (e.g., MATLAB, Minitab) and Microsoft applications. Work Environment Manufacturing environment works in a dynamic, hands‑on setting, combining office‑based analytical work with a heavy presence on the factory floor. Factory floor: The role demands a significant presence on the production floor, where conditions can vary. Potential conditions: Expect variable temperatures, loud machinery, and the presence of industrial equipment. Safety protocols: Standard personal protective equipment (PPE), such as hard hats, safety glasses, ear protection, and steel‑toed boots, are typically required. Emergency response: You must be available to respond to emergency calls to address critical production issues or equipment failures. Collaboration: Interaction is frequent and essential, involving collaboration with cross‑functional teams, including production managers, technicians, maintenance staff, quality assurance, and other engineers. Pace and demands: The environment is fast‑paced and can be high‑pressure, especially during new equipment commissioning, product launches, or major troubleshooting events. Success depends on strong problem‑solving skills, resilience, and adaptability. Seniority Level Mid‑Senior level Employment Type Full‑time Job Function Engineering and Information Technology Industries Manufacturing #J-18808-Ljbffr Samuel, Son & Co.