Controls Engineer PLC

JOB SUMMARY

• This role collaborates with Robotics, Process engineering groups and other team members to design controls systems to project specifications while mentoring and training entry level PLC Specialists.
  • Directly responsible for all aspects of PLC and HMI software design and development
  • Work with cross functional groups to ensure projects are completed on schedule
  • Create proposals, develop scope, costs, and initial design

KEY RESPONSIBILITIES

• Take lead in designing, sizing and selection of electrical equipment and controls systems for projects in accordance with project specifications and budget
  • Produce and maintain project drawings and documents including, electrical and controls schematics, control panel layout, PLC I/O layout, operation and maintenance manuals
  • Develop necessary controls documentation and programming for projects including PLC and HMI programs and sequence of operations
  • Coordinate all electrical and instrumentation design and scope requirements with vendors and internal project managers
  • Create network design for automated cell controls Ethernet I/P, Device Net, Profibus etc.

• Utilize new and developing technologies to drive continuous improvement through the organization to improve operational efficiencies in key areas of production. Working towards to goal of a fully automated Spray on Bedliner process
  • Implementation of a usable MES system to improve visibility of production from material usage to labor efficiency
  • Develop an internal training structure and course for employees
  • Work with existing vendors to improve current system functionality
• Support Production and startup activities of new equipment launches or updates at all GFX LTD/LLC sites
  • Develop comprehensive equipment testing procedures
  • Create and track start up and commissioning plan for plant use during initial implementation
  • Document and follow equipment orders for new projects
  • Resolve all internal or customer complaints related to projects in a timely and cost-effective manner
  • Create recommended spare parts and critical spare parts lists
  • Ensure equipment is running at optimal efficiency
• Provide continuing technical support with commissioning and validation of equipment system operation at Ground Effects sites
  • Familiar with remote network access systems 
  • Able to travel throughout North America to plant site where equipment is installed
  • Ability to establish remote access to ensure prompt response times to reduce downtime to minimum

• Ensure the Automation process is functional, well maintained and efficiently designed
  • Per the IATF16949 requirements, assist with ensuring that the production floor is equipped with proper functioning automation processes and other program designs.
  • Provide continuous review of departmental processes to improve overall efficiencies

QUALIFICATIONS

EDUCATION

Minimum Required:

• Bachelors degree in software engineering or related experience or training; or equivalent combination of education and experience
• Electrical and mechanical engineering experience

Preferred:

• 5+ years experience working in PLC software design electrical design & troubleshooting

EXPERIENCE

Minimum Required:

• At least 3 years experience as a PLC programmer
• 2+ years working in robotics/automation process
• Proficiency in CAD and AutoCAD software.
• Detailed knowledge of PLC automation software Allen Bradley RS Logix, Control Logix and Micro Logix

Preferred:

• 5+ years engineering experience in automotive manufacturing with robotics/automation.
• In-depth knowledge of manufacturing and mechanical processes.
• Knowledge of software design principals.

JOB SPECIFIC SKILLS

Minimum Required:

• Must have and maintain a valid Driver’s License
• Ability to travel internationally
• Excellent Communication skills, both verbal and written, are required to effectively communicate throughout the organization
• Ability to perceive needs and work independently
• Understanding of LOTO and basic electrical safety procedures
• Strong technical background and a clear understanding of a manufacturing process
• Fluent in English (verbal, reading, writing), (insert any other language requirements)
• Experience using a computer 

Required:

• Familiarity with TS16949 or IATF 16949, Quality Audits, and Environmental Management System and OSHA Requirements
• Proven engineering experience in Robotics/Automation in a manufacturing environment
• Experience with additional software platforms, Siemens, Omron, Mitsubishi, Red Lion, Maple Systems
• Fanuc Controls troubleshooting

COMMUNICATION & WORKING RELATIONSHIPS

• Communicate with engineering team, program management, and production team.
• Work closely with Operations Manager. Plant Managers, Engineering and Quality to ensure efficient automation processes.
• Providing input in continuous improvement in APQP meetings as necessary.
• Assist the Quality and Automation Teams, as needed, in the creation and implementation of automation and program design/processes work instructions.
• Effectively communicate with members at all levels of the organization to effectively convey ideas and troubleshoot issues 

WORKING CONDITIONS

The following working conditions are present or expected on a daily basis:

• Manufacturing/production floor environment with a presence on the production floor required for at least 20% of daily work time.
• Limited exposure to industrial manufacturing, automotive vehicles, weather elements, chemicals and robotics.
• Personal protective equipment must be worn at all times on the production floor.