With supervision from the Group Manager, Project Manager and more senior engineers, participate in the preparation and development of controls-related project deliverables, ensure project deliverable quality and perform project assignments. The Process Controls Engineer participates in meetings, provides feedback to management, engineering and project team members, works with other engineers, performs control system-related engineering calculations, design development and implementation.
**Primary Responsibilities**
* Understand basics of mechanical systems and manufacturing processes for which control systems will be designed. Influence mechanical designs where necessary for control considerations. Mechanical systems could include: paint and coating application process and equipment; conveyors and material handling and delivery equipment; line display equipment; fluid handling and fill equipment; waste treatment processes and equipment; as well as pneumatic and hydraulic applications.
* Understand and be familiar with governmental electrical and safety codes + standards.
* Understand and be familiar with client specifications and safety codes + standards.
* Maintain project records as well as daily personal records of communications and directions given and received.
* Understand contract documents and project records.
* Participate with project team and client as directed to prepare or edit project specifications and reports in both text and graphical formats.
* Participate in the design of operation concepts and requirements, general system flows and detailed sequence of operations.
* Specify and design control and power distribution system demolition and rework.
* Specify and design hardwired and software-based machine level control systems. Produce complete documentation drawing package.
* Specify requirements for PLC and PC programming and relate purchased software.
* Specify and design HMI screen/display arrangements and requirements.
* Schematic design and specify Network systems for communication and control.
* Schematic design and specify upper level production support systems (FMCS, PFS, QAS, PDS, AVI, etc.).
* Specify and design power distribution to and within production and process equipment. Perform calculations and designs relative to diversity factors, bus loading, voltage drops, circuit protection and coordination, feed sizing, distribution equipment sizing, etc.
* Specify and design lighting systems for industrial production applications.
* Specify and design control and power distribution system installation work.
* Provide budget estimate input for control systems and related installation work.
* Provide project scheduling input for control systems implementation.
* Track and communicate project status, both internally and externally.
* Review and approve contractor engineering submittals.
* Review and approve fabrication facilities and production equipment prior to shipment to site.
* Aid in the management and scheduling of resources, including internal and external engineering, contractors, vendors and skilled trades to complete projects in a timely manner.
* Participate in system start-up, debug and testing, and provide system review and punch-listing.
* Produce, or review and approve system as-built/as-installed drawings.
* Perform field checking of existing equipment, sites and facilities.
* Must be able to travel and accept field assignments to promote project success.
**Required Education and Experience**
* Associates Degree in a technical field with 7-12 years of related work experience, or a Bachelor Degree in an engineering discipline, with 5-10 years of related work experience.
**Additional Skills**
* Proficient in conveyor controls and/or paint process controls design and engineering
* Previous Automatic Vehicle Identification (AVI), Quality Audit systems (QAS) and Plant Floor systems (PFS) experience preferred.
* Previous experience with PLC’s (e.g., Allen Bradley PLC-5 and Control Logix family, Siemens S series), networks (Profibus, Ethernet, DeviceNet, etc.) and related software required. Training certificates required.
* Proficient in AutoCAD, MS Outlook, basic MS Excel (calculations, functions, sorting, formatting), MS Word (basic formatting).
* Good verbal and written communication skills.