Bulk Operations Controls Engineer

Job Description:

The Controls Engineer is responsible for ensuring the plant control systems are operating at a level which meets the daily needs of plant operations. The Controls Engineer provides advanced technical support and training to the plant maintenance personnel as needed. Responsible for initiating and developing improvements for existing production equipment and participating in the design of new equipment. This person will be on call as required to support 24 hour operations. The main focus for the Controls Engineer is equipment running on Siemens platforms, Leak Detectors, Card Splitters, Flow Meters and the PC’s attached to the BFS Machines.

Responsibilities:

• Obtain and maintain knowledge of all control systems and support equipment used in Bulk Operations.

• Ability to troubleshoot problems related to PLCs, HMIs, Ethernet communications, sensors, robots, servo drives, and vision systems.
• Develop / maintain documentation of systems that fall under Bulk Controls Engineer responsibility.
• Develop / maintain disaster recovery plan for systems that fall under Bulk Controls Engineer responsibility.
• Conduct investigations into equipment problems and failures to develop a plan to analyze equipment condition and minimize exposure to future reoccurrences.
• Ensure that the processes in the plant do not deviate from the validated conditions, and utilize the change control process as required.
• Identify areas for process improvements through analysis of efficiency data and process review. Includes improving equipment performance, preventing human errors, and creating troubleshooting tools.
• Work with the Quality departments to ensure accurate and timely information is provided to ensure and verify the quality of finished product.
• Change Control Documentation: Author and shepherd documents through the approval process. Update SOPs to reflect new automated sequences.
• Data Collection: Map and bridge PLC tags to SCADA and SQL databases. Develop automated logic to track Overall Equipment Effectiveness, downtime reasons, and scrap rates. Create intuitive dashboards to monitor real-time production health and bottleneck trends.
• Help troubleshoot equipment stoppages and assist in returning equipment to operation.
• Develop tools to aid troubleshooting equipment stoppages.
• Follow all SOPs, safety and health guidelines, and cGMP guidelines.
• Available on-call to support 24 hour operations.

Qualifications:

• BS degree in Engineering with at least two years experience in supporting manufacturing operations.
• PLC programming using Siemens is required. Experience with Allen-Bradley RSLogix is preferred.
• High speed packaging and pharmaceutical experience is preferred.
• Ability to establish priorities and meet quality expectations with minimal supervision.