Process Controls Engineer

Job Description

Process Controls Engineer

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Position Overview

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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.

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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.

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Key Responsibilities

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

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

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

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