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.
- Develop, test, and document PLC programs, control logic, and operator interfaces for both new and existing equipment.
- Diagnose and resolve mechanical, electrical, instrumentation, and controls-related issues to minimize downtime and improve equipment reliability.
- Partner with maintenance and operations teams to implement repairs, upgrades, and process improvements with minimal impact to production.
- Create, update, and maintain technical documentation including P&IDs, control narratives, electrical schematics, logic diagrams, network drawings, and equipment documentation.
- Integrate production equipment into facility networks to support remote monitoring, automation, data collection, and process control.
- Manage control system backups, software updates, version control, and change management activities.
- Develop and maintain interfaces that collect operational data from production equipment into databases, historians, and reporting systems.
- Analyze operational and process data to identify opportunities for increased efficiency, improved yields, greater throughput, and enhanced process stability.
- Support commissioning, startup, validation, and optimization of new equipment, automation systems, and process modifications.
- Train operators and maintenance personnel on automation systems, troubleshooting procedures, and best practices.
- Collaborate with third-party contractors, control system integrators, and equipment vendors on automation-related projects.
- Evaluate and recommend emerging automation technologies that improve manufacturing performance.
- Participate in root cause investigations, safety initiatives, and continuous improvement activities.
- 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.
- Experience supporting manufacturing equipment, automation systems, process controls, or industrial instrumentation in a production environment.
- Working knowledge of:
- PLC programming and troubleshooting
- HMI and SCADA systems
- Industrial instrumentation and process controls
- Electrical control systems and industrial networking
- Ability to read and interpret:
- P&IDs
- Electrical schematics
- Control narratives
- Logic diagrams
- Network drawings
- Strong troubleshooting and problem-solving skills in industrial environments.
- 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.
- Hands-on experience with Allen-Bradley, Siemens, ABB, or similar PLC platforms.
- Experience with HMI and SCADA software such as FactoryTalk, AVEVA InTouch, Wonderware, Ignition, or comparable systems.
- Knowledge of industrial communication protocols including Ethernet/IP, Modbus, Profibus, and related technologies.
- Familiarity with operational technology (OT) cybersecurity principles and best practices.
- Experience with manufacturing data collection systems, process historians, SQL databases, dashboards, or analytics platforms.
- Experience supporting equipment commissioning, startup, and validation activities.
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Technical Skills
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- PLC programming, commissioning, troubleshooting, and optimization.
- HMI and SCADA development, alarm management, and operator interface design.
- Industrial instrumentation calibration and troubleshooting.
- Process control strategy development and implementation.
- Root cause analysis and corrective action execution.
- Preventive and predictive maintenance of automation systems.
- Industrial networking and communication protocols.
- Manufacturing data collection, reporting, and process analytics.
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