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.
• He or she 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 strategies.

• They will also be responsible for developing and maintaining the Plant Capex forecast for all on-going capital projects.

Essential Functions of the Job:

• Develop and implement standard electrical, mechanical and automation engineering practices.
• Manage automation improvement projects.
• PLC logic programming, with Allen-Bradley Systems and Hardware.
• 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 on frequency.
• 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, provide integration support with existing equipment, as necessary.
• 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 team and the Automation Controls Specialistin 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 and professional training on Allen Bradley machine controls (PLC's/VFD's).
• Certification or training on Plant Electrical Systems.
• 7+ 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.
• Aseptic and/or high-speed beverage maintenance experience.
• Successful commissioning and startup automation experience.

• Knowledge of mechanical, electrical and controls technologies and design application.
• Experience with scoping, designing, budgeting and project managing a variety of Capex projects within a manufacturing environment to support different internal customers.
• Extensive experience working with vendors and contractors in a variety of different fields to deliver engineering project solutions.

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).
• TMP or LEAN manufacturing experience, Green or Black belt certified.
• Familiarity with instrumentation and thermal processing equipment such as processors, fillers, batching and packaging equipment (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.
• Skilled in organizing resources and establishing priorities.

• Experience with Tetra thermal processing plus systems and fillers as well as Tetra Plantmaster.

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 are required.
• 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.
• Demonstrated results of solving complex technical issues.

• Tetra VTIS and Flex Thermal Processors and batching systems.
• Tetra high speed 1,000ml, 1500ml and 2000ml castor fillers.

Additional Considerations:

• Travel Requirements: Up to 10%.
• Location: This position will be at our SunOpta Plant in Allentown, PA.
• Relocation or international remote working arrangements (outside of the US) will not be considered.

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.