Controls Engineer - Paint

The Paint Controls Engineer will also work with cross-functional teams throughout the entire lifecycle of the product and processes. The individual will work closely with Process Engineering, Quality and Production at the Paint Shop, from initial design, through development , commissioning and finally into full production. You will be working to develop and improve new and existing equipment, processes and industrial manufacturing automation concepts for Paint Shop along with Manufacturing Engineers and suppliers. You will be responsible for creating a robust system architecture to support the equipment concept, and then evaluate the layout of electrical/pneumatic schematics. This individual will lead the process of the electrical panel manufacturing, as well as lead the software development and implementation for all equipment controls components such as PLC, safety devices, HMI, servo drives, process hardware and robots from power-on to commissioning, and finally production trial and acceptance release.

Responsibilities:

• Lead initial electrical equipment conceptual development and product specifications, process requirements, layout, cost, and timeline
• Optimization of our paint shop value stream layout and production flow with the use of industrial controls and automation
• Close coordination with process engineers, manufacturing interdisciplinary teams and MEP/Facilities to ensure the design intent and project scope is accomplished focusing on automation
• Implementation and guidance on solutions for conveyance and material handling automatic equipment such as hoists, robotics and Paint shop manufacturing processes (sanding, sealing, coating, curing)
• Develop electrical control panels which are NFPA79/NEC/UL508A compliant, and create electrical, pneumatic and fluid schematics
• Architect, write, and debug PLC ladder logic focused on generating code that is organized, structured, documented, maintainable and reusable. PLC code will interact with subsystems such as conveyors, robots, Manufacturing Execution System (MES), machine vision, and 3rd party equipment
• Implement (ANSI/RIA15.06/OSHA compliant) control reliable safety systems for safeguarding robots, gantries, conveyors, and other high volume manufacturing equipment
• Generate aesthetically simple HMI screens for complex machinery while providing sufficient feedback for troubleshooting
• Manage electrical cabinet builds, field wiring, pneumatic and fluid plumbing
• Select and size electrical and electromechanical components such as servos
• Introduce automated processes into production, and train and equip Sustaining Team to support automated equipment after deployment into production
• Establish the equipment interfacing from the shop floor to Manufacturing Execution System (MES) to communicate production, machine status, and process variables
• Generate specifications and release to Vendor for quotation and technical evaluation
• Coordinate and supervise suppliers during specification, design, buyoff and installation of Industrial Controls Equipment
• Architect and validate new automated process control equipment for deployment into production
• Optimize industrial control system to maximize cycle time and uptime
• Provide detailed utility layouts for paint shop equipment interface to the building and support the facilities team with the implementation
• Implement data traceability and tracking communications network solutions and interface with cross-functional team for materials, product, industrial Engineering and quality
• Document generation for training, equipment maintenance and troubleshooting

Basic Qualifications:

• Bachelor's Degree in Electrical Engineering, Mechatronics, Automation, and Robotics or related field with emphasis in Industrial Process Controls
• 5+ years' demonstrated experience working with Industrial Control systems
• Knowledge of Electrical and Equipment Manufacturing Standards (ISO, NFPA/ANSI, National Electric code, UL508A, NEMA, IEC)
• Knowledge of Safety standards (ANSI/RIA15.06, OSHA, IEC)
• Electrical schematics design, interpretation and revision experience
• Proficiency with electrical and fluid schematics in CAD (ePLAN, AutoCAD Electrical software packages)
• Proficiency with Ladder logic software development environment for PLCs (Siemens S7/TIA Portal, Allen-Bradley)
• Shall have a clear definition of how to implement code in reusable and structured standardized way. Use of sequencer and state machines for paint processes which involve interlocking, continuous process automation, data acquisition, and PID control
• Human Machine Interface (HMI / GUI - WinCC, Ignition)
• Industrial Field Networks (Profinet, Sercos, Modbus/TCP, Safety rated networks)
• Serial communication  (RS-232), Ethernet TCP/IP sockets and stack
• SQL Database design, configuration and management
• Proven ability to design fault-tolerant systems with error handling and recovery
• Proficiency selecting appropriate circuit protectors, wire and cable, sensors, safety devices, PLC CPU/Network Cards and remote I/O. Programming and fine tuning VFD, servo systems etc. Familiarity with IP20 and IP67 based systems
• Experience with a wide variety of production machinery, industrial sensors, and equipment (LVDT and pressure transducers, dispense systems, temperature controllers, PID, Pump/Fans and power meters)

Preferred Qualifications:

• Experience programming robots (Fanuc, Motoman, DURR, Kuka)
• Experience in Automotive Manufacturing industry 
• Experience in Pretreatment, Electrodeposition Coating, WWT, Sealing and Paint Application Process 
• 3D CAD packages SolidWorks, Delmia and CATIA 
• Experience with Vision systems (Cognex, Keyence)
• Manufacturing KPI and Metrics knowledge
• Data Statistical quality control, capacity analysis, repeatability, industrial engineering and lean manufacturing concept knowledge 
• Handling of robotics computer assisted software, applications development package and industrial field networks ability
• A creative curiosity, collaborative ethic, hardworking enthusiasm, and driving personal vision
• Excellent communication skills and team-working tendencies
• A penchant for multi-tasking and self-starting
• A genuine fascination for the Environmental and Safety field and a commitment to global change
• A true sense of determination… and hopefully a sense of humor