Controls Engineer

The Controls Engineer will be primarily responsible for the support, troubleshooting and integration of automated manufacturing process control systems in the designated manufacturing production facility. This position will provide engineering expertise to assist plant-level Maintenance, Production/Operations, EH&S, and management personnel in identifying and solving technical process issues. This position will also provide support for the design, commissioning and startup of small-to-large scale capital expenditure projects in conjunction with Central Engineering. Technical assistance will require basic understanding of plant power distribution systems and process/machinery control systems. A practical level of understanding of mechanical and electrical engineering principles are to be applied to assigned project work.

Essential Duties

• Troubleshoot and resolve issues with existing process equipment and control systems.
• Provide training and technical assistance to plant-level Maintenance, Production/Operations, EH&S, and management personnel.
• Project management that includes scope development, funding requests, and execution.
• Design using the latest hardware and software components, design machine control systems to maximize equipment productivity and assure all code requirements and safety standards are strictly met.
• Assist plant with the development of goals, objectives, and schedules for potential projects/upgrades.
• Coordinate day-to-day activities of contractors and plant maintenance personnel during project execution.
• Travel to Carlisle Construction Materials facilities outside of home base office, in support of project planning, equipment installation, startup, and training.

Core Competencies

Essential Full Performance Knowledge:

• Proficient in Rockwell Automation software and Allen-Bradley hardware.
• Proficient in general industrial controls, manufacturing processes
• Programmable Logic Controllers (PLCs)
• Human Machine Interfaces (HMIs)
• Industrial communication protocols (Ethernet/IP, ControlNet, DeviceNet, Profibus)
• Basic understanding of open/closed control loops (PIDs)
• Understanding of electrical wiring principles based on the National Electric Code (NEC)
• Data Historian development
• Basic understanding of low-voltage power distribution
• Software/Data communication protocols (OPC-UA/OPC-DA)
• Basic understanding of AutoCAD
• Ability to stay abreast of new development in controls/technology

Essential Full Performance Skills:

• Programming of basic control system logic (ladder logic, structured text, function block)
• Configuration and tuning of variable frequency drives (VFDs)
• Interpretation of electrical/controls drawings
• Interpretation of mechanical design drawings for electrical requirements
• Understanding and evaluation of component, equipment or installation proposals
• Utilize and interpret technical data sheets and manuals
• Basic project management skills
• Basic problem-solving skills
• Basic analytical comparison and value judgment skills

Equipment Used

• Industrial computers/laptops
• Electrical/wiring test equipment such as multi-meters, scopes
• General maintenance tools (screw drivers, tape measures, hand tools)

Working Conditions

The basic work environment is within a manufacturing facility with an average of 1 week of travel per quarter (although more travel may be required on occasion). The atmosphere is relatively fast paced and occasionally becomes stressful. The environment demands that multiple projects be worked on at the same time.

Work Environment:

• 70% factory – process equipment, support, troubleshooting, programming/testing.
• 30% office – project development, monthly reports, projects updates, team meetings/calls

Time Worked:

• Hours Worked: Normally 8:00 a.m. to 5:00 p.m. | 40 hours/week; Situations will require additional hours worked per day and /or alternate shifts worked (equipment breakdowns, process issues/troubleshooting, equipment commissioning/startups, etc.).
• Days of Week Worked: Monday through Friday; Saturday/Sunday work to support production needs occurs occasionally.
• Comments: Work is in a fast-paced production environment, sometimes stressful and always demanding. Incumbent is on-call for process upsets not resolvable by maintenance.

Physical Requirements

• Walking across plant to observe manufacturing process and on catwalks to observe equipment function.
• Climbing stairs and ladders to access equipment and roofs.
• Stooping - equipment observation.
• Kneeling -production observation.
• Standing - Occasionally for extended periods to observe process.
• Lifting - 50 lbs. or more.
• Sitting - Office work, reports, computer.

Personal Protective Equipment (PPE) Used

• Clear (non-tinted), Gasketed Safety Glasses
• Steel-Toe Shoes
• Safety Gloves
• Flame Retardant Uniform
• Arc-Flash PPE

Minimum Requirements

Education:

• BA/BS degree in engineering or related discipline (BS in Electrical Engineering is preferred)
• Equivalency – Five years of direct practical experience in the industrial controls/automation industry.

Experience:

Minimum of five years industrial/manufacturing experience in a controls engineering capacity.