Engineer II, PLC Automation

Summary:

The Engineer II, PLC Automation is an ESMI-based controls engineer responsible for providing specialized automation and technical support to Our Partner and affiliated manufacturing entities throughout North America.

This position supports the development, deployment, commissioning, startup, stabilization, troubleshooting, and optimization of PLC-based control systems used in lithium-ion battery electrode mixing processes. The Engineer serves as a technical expert in Our Partner electrode mixing control programs, PLC and HMI systems, recipe management, alarm management, NMP process control, automated material handling, and manufacturing-system communications.

The Engineer travels to North American manufacturing sites to support new-line launches and production ramp-ups, resolve complex control-system and process-automation issues, implement control-logic improvements, and transfer specialized knowledge to locally hired controls engineers and maintenance personnel.

Responsibilities:

Provide PLC, HMI, and automation engineering support to ESMI and other Our Partner or affiliated North American manufacturing entities.

Support the installation, setup, I/O checkout, commissioning, startup, acceptance testing, and production stabilization of electrode mixing equipment.

Develop, modify, test, and troubleshoot PLC programs using Mitsubishi, LS ELECTRIC, Siemens, and other applicable control platforms.

Develop and modify HMI and SCADA applications using GP-Pro EX, Mitsubishi GOT, XP-Builder, TOP Design Studio, AVEVA InTouch, CIMON, Weintek, and comparable systems.

Develop, modify, and optimize electrode mixing control sequences, including cathode binder mixing, premixing, slurry transfer, additive pre-weighing, active-material feeding, and automated RPM-change functions.

Develop and maintain communication maps and control programs between mixing-equipment CPUs, auxiliary equipment, and manufacturing IT systems.

Develop, modify, and commission ROS functions and related equipment interfaces based on production and customer requirements.

Perform full-equipment I/O checkout and validate sensors, actuators, valves, motors, inverters, interlocks, alarms, and equipment operating sequences.

Develop and troubleshoot industrial communication systems using RS-485, Modbus TCP, inter-CPU communications, and other applicable industrial protocols.

Support the integration of mixing equipment with conveyors, AGVs, auxiliary systems, production-reporting applications, and related manufacturing equipment.

Diagnose and resolve complex PLC, HMI, SCADA, network, communication, I/O, sequence, equipment-interface, and process-control issues.

Analyze recurring equipment faults, process interruptions, control failures, and production losses; conduct root-cause analysis and implement corrective and preventive actions.

Modify control programs and operating sequences to improve process stability, equipment reliability, cycle time, production efficiency, and product quality.

Support equipment model changes, process modifications, hardware upgrades, and customer-requested control-system changes.

Review and update PLC programs, HMI applications, control-panel drawings, electrical drawings, I/O lists, communication maps, alarm lists, and technical specifications.

Maintain controlled records of PLC and HMI software versions, program changes, parameter modifications, testing results, and corrective actions.

Coordinate technical activities with manufacturing, maintenance, process engineering, equipment engineering, IT, equipment suppliers, contractors, and engineering teams across multiple entities.

Train and provide technical guidance to locally hired controls engineers, technicians, maintenance personnel, and subcontractors on equipment operation, PLC architecture, troubleshooting, and control-system maintenance.

Provide on-site technical support during new plant launches, production ramp-ups, major control-system failures, and other critical manufacturing events.

Travel frequently to manufacturing facilities throughout North America based on project and operational requirements.

Required Skills:

Strong PLC programming and troubleshooting skills using Mitsubishi GX Works2 and GX Works3, LS ELECTRIC XG5000, or Siemens TIA Portal.

Working knowledge of Allen-Bradley PLC maintenance and troubleshooting.

Knowledge of PLC-based control systems used in lithium-ion battery electrode mixing or comparable automated process-manufacturing operations.

Experience developing and modifying electrode mixing sequences, material-transfer logic, ingredient-feeding functions, or comparable batch-process automation.

Strong HMI development and troubleshooting skills using multiple industrial HMI or SCADA platforms.

Experience conducting full-equipment I/O checkout and validating sensors, actuators, valves, motors, inverters, alarms, and interlocks.

Experience developing and troubleshooting RS-485, Modbus TCP, inter-CPU, and equipment-interface communications.

Ability to develop communication maps and integrate production equipment with auxiliary equipment and manufacturing IT systems.

Experience with ROS, conveyor, AGV, servo, or other automated equipment interfaces.

Ability to diagnose PLC, HMI, SCADA, industrial network, I/O, equipment-sequence, and process-control issues.

Ability to read and update electrical schematics, PLC-panel drawings, I/O lists, network diagrams, and technical specifications.

Working proficiency with AutoCAD for automatic-control and PLC-panel drawings.

Strong root-cause analysis, change-control, technical documentation, and production-support capabilities.

Ability to provide hands-on technical training and transfer specialized control-system knowledge to local personnel.

Ability to work effectively across multiple manufacturing sites, corporate entities, cultures, and technical functions.

Qualifications:

High school diploma or equivalent required. An associate or bachelor’s degree in computer science, electrical engineering, controls engineering, automation engineering, mechatronics, or a related field is preferred but may be substituted with substantial directly relevant experience.

At least 5 years of progressively responsible experience in PLC programming, industrial automation, manufacturing control systems, commissioning, or related equipment-engineering functions.

Demonstrated experience developing, modifying, commissioning, and troubleshooting PLC and HMI systems in automated manufacturing environments.

Demonstrated experience with at least two major PLC platforms, such as Mitsubishi, LS ELECTRIC, Siemens, or Allen-Bradley.

Experience supporting lithium-ion battery manufacturing, electrode mixing equipment, automated material-processing systems, or comparable process-manufacturing equipment.

Experience performing equipment I/O checkout, communication testing, commissioning, production startup, and manufacturing-line stabilization.

Experience supporting control-system projects at multiple manufacturing facilities or international locations.

Ability to interpret electrical drawings, PLC-panel drawings, I/O lists, communication maps, and equipment technical documentation.

Ability to communicate effectively in English in technical and operational settings.

Ability and willingness to travel frequently throughout North America.

Ability to work flexible or extended hours during equipment installation, commissioning, production ramp-up, control-system failures, and other critical project periods.

Benefits

Medical / Dental / Vision: 100% employer contribution starting on the first day of employment

Paid Holidays: 17 days per year

PTO: 15 days per year

Relocation Bonus: $3,000–$5,000 depending on distance

401(k): 3% employer match

Visa Sponsorship: Available for eligible candidates

Our Partner is an Equal Opportunity employer that values the diversity of its workforce.