Manufacturing Engineer

Overview

We are currently seeking a Manufacturing Engineer to join our team in our Madison manufacturing plant.In this role you will manufacturing projects while serving as a key technical resource for daily operations. This role is responsible for managing the design, procurement, installation, and implementation of automation, controls, equipment, and process improvement initiatives, while balancing project priorities with operational support needs. The Manufacturing Engineer also acts as the onsite troubleshooting expert for complex equipment and manufacturing system issues escalated beyond Maintenance and Manufacturing Engineering Technicians, driving sustainable solutions that improve safety, quality, productivity, and reliability.

This position will be 100% onsite at our Madison, WI Manufacturing Facility.

Responsibilities

• Design, development and programming of PLC and touchscreen based automated controls, specifically:
  • Development and documentation of needed processes.
  • Selection of appropriate PLC, GUI touchscreen, sensors, user interface, servo mechanism, motor, motor starters, variable frequency drives and enclosure.
  • Develop of control input/output list.
  • Using sound engineering principles, current technology and AprilAire documentation standards provide CAD documentation of conceptual control systems.
  • Manage fabrication of control system.
  • Development of PLC and/or GUI touch-screen code based on process.
  • Perform first I/O test of PLC and/or GUI touchscreen.
  • Debugging and implementation of control system.
  • Documentation of final control system.
  • Development of training documents for Maintenance and Production Staff.
• Manage projects where you and/or outside contractors or internal resources are responsible for the design, fabrication, programming, and implementation of manufacturing equipment, specifically:
  • Conformance of equipment to AprilAire standard components and programming specifications.
  • Equipment compliance with OSHA, ANSI, and NEC safety standards.
  • Adherence to project timeline and budget.
  • Appropriate equipment operation for production staff.
  • Conformance of end product to AprilAire quality standards.
  • Documentation required to turn equipment over to Production/Plant Maintenance.
  • Updating Manufacturing Management concerning the status of the project.
  • Managing the activities of Maintenance Staff and/or Plant Engineering Technician(s) assigned to projects.
• Propose manufacturing equipment projects including identification of equipment projects, development of project cost, timeline, resources, savings, and payback, and preparation and submittal of proposal to Manufacturing Management.
• Serve as the highest-level controls/electrical troubleshooter before vendors are contacted and a resource for Maintenance and Manufacturing Engineering Technicians to problem solve unknowns, support troubleshooting methodology, and train when root cause is found.
• Troubleshoot automated control systems, specifically:
  • Safely troubleshoot 480V 3 phase, 230V 3 phase, 240V and 120v, along with controls 24VDC to root cause failures
  • At times follow through with full remediation of root cause failures without assistance
  • Modify PC, PLC, and touch–screen software as required to support Plant Maintenance and needs of Production Staff.
  • Identify and specify available replacement components for obsolete or unavailable components.
  • Maintain records of modifications to existing automated control systems.
• Work collaboratively with Design Engineers, Product Engineers and other departments as required to maintain product quality and manufacturing efficiency.
• Perform such liaison as may be required to obtain information, services, and materials necessary for projects by telephone, travel to or visits by vendor representatives.
• Diagnose production problems and recommend solutions to these problems.
• Keep abreast of and well informed on new developments in machine design and controls.
• Conduct basic research and development work on mechanical/electrical systems to provide optimum efficiency for manufacturing equipment or processes.
• Safely fabricate components utilizing machine shop equipment (vertical mill, lathe, brake, bandsaws, other hand equipment) when cost effective.
• Complete machines and devices, requisition parts, assemble and finalize functional unit.
• Search for and investigate new sources of suppliers of parts, tools, electrical components, etc., who may provide cost reductions on goods compared to current suppliers.
• Represent the Manufacturing Department as a member of product design teams as assigned.
• Recommend operational efficiencies and react promptly to any concerns by the department.
• Practice safety and make safety a primary concern in all projects.

Qualifications

• Bachelor’s degree in manufacturing, mechanical, electrical, or controls engineering, or other closely related discipline, or an equivalent combination of education and experience.
• 2+ years of general manufacturing machine or process design experience required to assure full project accountability from concept through project completion.
• Valid driver’s license.
• Knowledge of design techniques, tools, and principles involved in the development of automated control systems.
• Knowledge of drafting standards.
• Knowledge of machines and tools, including their designs, uses, repair, and maintenance.
• Knowledge of circuit boards, processors, chips, electronic equipment, and computer hardware and software, including applications and programming.
• Knowledge of selection, programming, implementing, and troubleshooting PLCs and user interface touch screens.
• Ability to identify measures or indicators of system performance and the actions needed to improve or correct performance, relative to the goals of the system.
• Ability to determine how a system should work and how changes in conditions, operations, and the environment will affect outcomes.
• Ability to manage one’s own time and the time of others.
• Ability to arrange things or actions in a certain order or pattern according to a specific rule or set of rules (e.g., patterns of numbers, letters, words, pictures, mathematical operations).
• Strong mathematical skills, including:
• Ability to work with mathematical concepts such as probability and statistical inference, fundamentals of plane and solid geometry and trigonometry.
• Ability to apply concepts such as fractions, ratios, and proportions to practical situations.
• Ability to choose the right mathematical methods for formulas to solve problems.
• Very strong problem-solving skills, including:
• Ability to define problems, collect data, establish facts, and draw valid conclusions.
• Ability to interpret an extensive variety of technical instructions in mathematical or diagram form and deal with several abstract and concrete variables.

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