Senior Controls Engineer

Job Summary:

The Senior Controls Engineer is responsible for the manufacturing automation and controls systems design, specification, documentation, programming, simulation, testing, and start-up assistance.
This role will provide factory and departmental leadership, particularly in maintenance guiding the Information Systems Manager and Instrumentation & Controls Technicians.
The Senior Controls Engineer possesses operational, technical equipment, process, troubleshooting, and automation systems programming expertise.
They assist enterprise-wide with managing and overseeing operational automated controls and capital project programming protocols and installations, as well as manufacturing-related processes.
The Senior Controls Engineer plans, directs, documents, and coordinates the day-to-day operations of the Information Systems Manager and Maintenance Instrumentation & Controls Technicians.
They are responsible for ensuring and improving the overall efficient performance, productivity, and operational compliance of the plant automation through the provision of effective methods, controls, and strategie

Essential Functions of the Job:

Develop and implement standard electrical and automation engineering practices.
Manage automation improvement projects.
PLC logic programming
Design, configure, integrate, and implement process control solutions for various manufacturing specifications.
Develop control system validation/testing protocols.
Familiar with TCP/IP, Modbus, and Devicenet communication protocols.
Experience with controls and calibration utilizing best practices per relevant IEEE and IEC standards.
Practical experience integrating transducers of types such as pressure, temperature, conductivity, PH, and flow with automated systems.
Experience with developing and modifying Add on instructions for PLC logic.
Proportional Integral Derivative (PID) tuning and applications.
Responsible for 3rd party calibration of transducers per company guidelines.
Provides reliability engineering expertise that supports our maintenance and reliability efforts and assures asset life at or beyond the standards.
Integrating VFD's with PLCs in automated processes, to include acceleration deceleration tuning, and HMI screens for operator interface.
Responsible for Factory Acceptance Testing and Provisional Acceptance Testing approval for newly installed 3rd party equipment to ensure fulfillment of contract specifications, providing integration support with existing equipment, as needed.
Collaborates with cross-functional groups including Production, Human Resources, Quality, Supply Chain, Warehouse, and Finance to meet production targets.
Develops, recommends, and implements measures to improve machines and plant equipment to maximize efficiency.
Lead, coach, and manage the performance of the maintenance Instrument Control Technician team in a fast-paced, dynamic environment.
Train operators, managers, and IC Technicians on control systems
Oversees installation, modifications, quality control testing, operating procedure, and inspection processes adhering to engineering principles and safety regulations.
Serves as a safety model, promoting a high level of safety awareness and continuous improvement in safety practices.
Ensures effective employee relations. Provides employee coaching and development. Resolves employee issues through problem resolution.
Responsible for Food safety and quality of food. Demonstrates a commitment to Quality.
Facilitates coordination between maintenance and operations in solving process issues.
Adheres to company GMP's (good manufacturing practices), safety procedures and all other quality processes.
Continuously improve process control systems through Advanced Process Control, Alarm Management, and Operator Interface Optimization
Design, write programs, implement, test and document PLC and HMI or SCADA software of any of the following software packages: Rockwell, Factory Talk
Create, edit, and document batch systems recipes.
Serve as a resource and a technical expert for the plant in all disciplines of automation controls for line, utility support, and process equipment.
Wear PPE (Personal Protective Equipment) when required.
All other duties, as assigned.

Minimum Qualifications:

Bachelor's or Associate degree in Industrial Controls, Electronics, Engineering, Technology or related disciplines or training on Allen Bradley machine controls (PLC's/VFD's).
Certification or training on Plant Electrical Systems.
5+ years of applied industrial controls experience using Allen Bradley control platforms (SLC500, ControlLogix, MicroLogix, PanelView Plus, RS Logix, RS View), Motor Control experience with Servo and VFD devices.

Preferred Qualifications:

Certified Professional Engineer
8+ years of experience directly related to the duties and responsibilities specified required.

Knowledge of and familiarity with the National Electric Code (NEC) and international standards.
Proficiency designing and programming control systems with emphasis on PLCs, SCADA, or HMI systems.
Ability to troubleshoot control systems from the field element up through operator interfaces and databases.
Proficiency with control system networking technologies and PC networking technologies.
Proficiency working with SQL Server, Oracle, or other relational databases.
Familiarity with dairy productions processes, Clean In Place (CIP)
Familiarity with instrumentation (flow meters, level transmitters, RTDs/temperature transmitters, level probes, etc.).
Excellent written and verbal communication skills
Specific knowledge of GMP's and batch process control in the food science industry with validation experience is a plus.
Skilled in organizing resources and establishing priorities.

Knowledge and Skills:

Programming experience primarily with Allen Bradley ControlLogix, CompactLogix and SLC500 PLCs.
HMI or SCADA programming and configuration.
Allen Bradley PowerFlex VFDs.
Knowledge of and familiarity with the National Electric Code (NEC) and international standards.
Proficiency designing and programming control systems with emphasis on PLCs, HMI systems.
Experience and demonstrated knowledge of thermodynamics and mechanics is required.
Knowledge of Lean Manufacturing practices is beneficial.
Strong verbal and written communication skills.
Working knowledge of RSLogix 500,5000, and Studio 5000 Factory Talk view, and Studio.
Basic network skills and troubleshooting.
Must have a working knowledge of MS Word, Excel, and PowerPoint software.
Prefer a candidate with SQF practical experience and training.
TPM or LEAN manufacturing experience is preferred.
Aseptic and/or high-speed beverage maintenance experience.
Successful commissioning and startup automation experience.
Demonstrated results of solving complex technical issues.

Additional Considerations:

Travel Requirements: Up to 10%.
Location: This position will be at our SunOpta Plant in Midlothian, TX.

Please note this job description is not designed to cover or contain a comprehensive listing of activities, duties or responsibilities that are required of the employee for this job. Duties, responsibilities, and activities may change at any time, with or without notice.