Electrical Automation Engineer

Job Overview

This individual is responsible for designing, programming, simulating, developing, testing and managing systems for automated machinery and processes within a manufacturing environment.  The role will collaborate with others and be responsible for designing/specifying, installing, documenting, and troubleshooting automation equipment for new and existing products and processes, developing conceptual designs, and translating into functional equipment and processes.  The position will improve plant and equipment operating efficiency by providing automation and engineering support to the plant operations.  He or she will develop and enhance process automation applications for present and future automation systems.  The role, in collaboration with others, is responsible for providing management with recommendations on technical advances to achieve or exceed company goals and maximize productivity.  Typical projects range from $100k to $1M.

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A Day In The Life

Automation Development

• Responsible for identifying and leading automated equipment projects to increase production capacity and improve product quality.
• Identify potential process improvement projects, design and develop programs to address findings.
• Work with Product Designers, Project Managers, and Manufacturing personnel to develop or refine product and equipment designs.
• Generate detailed Statement Of Work documents for internal approval and for bidding by outside vendors.
• Develop detailed capital justification and generate Appropriation Requests (ARs) for proposed projects.
• Design and programming of total automation control systems using AutoCad/AutoCad Electrical, and programming software, primarily RSLogix/Studio 5000. Control systems generally will include Rockwell CompactLogix PLCs, HMIs, VFDs, motor controls, safety system and components, and supporting sensors and pneumatics. System design will also often include Rockwell servo controls, vision systems, and Fanuc robots where appropriate.
• Generate justification for “make or buy” decisions.
• Manage automation projects built by outside custom automation vendors including concept work, equipment specification, project management, factory acceptance testing, installation, and commissioning/debug.
• Support operations through equipment startups and provide operator/maintenance training.
• Provide maintenance support and training for new equipment if needed.
• Develops/reviews/maintains/updates related documentation, files, procedures, databases, drawings and schematics in order to ensure integrity of units, instruments, and process control technologies.
• Build prototypes to prove complex/high-risk processes prior to final design.
• Complete assigned work within agreed upon schedule and budget while maintaining high level of quality.
• Determine where opportunities exist to implement automation by working closely with Product Designers, Project Managers, and Manufacturing teams.

 Manufacturing Operations Support

• Develop and implement long range plans for process control improvements.
• Guide and train designated employees on process control methodology to assist process control and quality improvement efforts.
• Develop/modify procedures, calibration, and training guidelines as needed for automation processes, including training of setup and maintenance personnel.

Project Management

• Provide leadership and communication to all project team members and functional managers such that the project objectives are clear, responsibilities are understood and progress is tracked and reported.
• Provides project team input on system capabilities and assist teams with system design decisions.

What will help you thrive in this role?

Education and/or Experience:

• Bachelor of Science degree in Automation, Controls, Electrical or other related engineering discipline. Mechanical engineers with the required controls experience will also be considered. BSEE degreed candidates with primarily automation equipment design experience are preferred.
• 8+ years in a manufacturing or system integrator environment with demonstrated ability developing and implementing automation processes and equipment.
• Possess plant maintenance and operation knowledge along with technical skills to perform assigned duties.
• Demonstrated knowledge and understanding of Machine Control engineering concepts and design including vision, safety systems, and motion control, as well as a general knowledge of mechanical equipment and systems

• Provide leadership and communication to all project team members and functional managers such that the project objectives are clear, responsibilities are understood and progress is tracked and reported.
• Provides project team input on system capabilities and assist teams with system design decisions.

Technical

• Solid knowledge in the Automation/Electrical Engineering Design field, with extensive technical experience in the design, optimization, and build of automation equipment.
• Interface with mechanical team to control the architecture design and implementation, ensuring the correct support of motion controller configuration, setup, fine tuning, data collection, data analysis and reporting, and equipment safety requirements.
• 5+ years’ experience specifying, designing, and programming with Rockwell Automation control products, including PLCs, HMIs, VFDs, Motion Control, and Safety products/systems.
• 3+ years’ experience designing control system schematics with AutoCad and/or AutoCad Electrical.
• Experience in any of the following areas are a definite plus (in order): Fanuc robot programming/troubleshooting, Fanuc (or other) vision system programming experience, hydraulic servo/proportional valve control, position feedback systems, high voltage product testing, HiPot/PD testing, LabVIEW, high speed data acquisition, analog circuit design and understanding of passive components, time and frequency domain analysis, 3D modeling with Autodesk Inventor or SolidWorks, MSAccess, MSSQL, web page coding/interfacing to MSSQL.