Asst Manager - Projects & Automation Control

Avery Dennison

3d•Onsite

About The Position

The Assistant Manager – Projects & Automation & Control- South Asia will be responsible for supporting and executing capital projects, automation initiatives, machine integration, and engineering improvement projects across the manufacturing facility. The role will work closely with Engineering, Operations, Maintenance, EHS, Quality, IT/OT, Procurement, Finance and external vendors across India locations to ensure projects are delivered safely, on time, within approved budget and in accordance with company engineering and quality standards. The position will have a strong focus on project execution, automation, controls, machine integration, commissioning and continuous improvement.

Requirements

Bachelor's degree in Electrical / Electronics / Instrumentation / Automation Engineering.
9-10 years of relevant experience in Projects, Automation, Controls or Engineering in a manufacturing environment.
Experience in capital project execution and machine automation.

Responsibilities

Support end-to-end execution of capital and engineering projects from concept through commissioning and project closure.
Execute brownfield projects including machine upgrades, capacity expansion, automation, utilities and process improvements.
Support greenfield projects related to plant infrastructure, production areas, warehouses and material handling systems.
Prepare project execution plans, schedules, action trackers and project documentation.
Coordinate daily project activities with internal stakeholders, contractors, OEMs and vendors.
Monitor project progress against approved scope, schedule, cost and quality requirements.
Identify project risks, delays and technical issues and ensure timely corrective actions.
Support project commissioning, production trials, performance validation and handover to Operations/Maintenance.
Lead/support automation and machine-control projects involving PLC, HMI, SCADA, drives, sensors and industrial communication systems.
Develop and review I/O lists, control philosophies, sequence logic and control architecture.
Coordinate with OEMs and system integrators for PLC programming, HMI/SCADA development and machine integration.
Support PLC programming, troubleshooting, modification and optimization.
Work with Siemens and Allen-Bradley PLCs, HMIs and drive systems.
Support integration of new machines with existing production lines and plant control systems.
Review PLC logic, interlocks, permissives, alarms and sequence control developed by OEMs.
Coordinate PLC-to-PLC communication and signal exchange between machines and plant systems.
Support industrial communication networks such as Profinet, Ethernet/IP and other applicable protocols.
Develop and maintain automation standards for machines and equipment.
Troubleshoot automation, PLC, VFD, HMI, communication and instrumentation issues during commissioning and production.
Lead/support integration of new equipment into existing manufacturing lines.
Define machine interface requirements, I/O requirements and communication protocols.
Coordinate with OEMs for electrical, instrumentation, PLC and communication interfaces.
Ensure proper integration of safety circuits, interlocks, emergency stops and machine permissives.
Conduct FAT, SAT and commissioning activities with OEMs and system integrators.
Ensure successful machine handover to Maintenance and Operations teams.
Support preparation of project proposals, feasibility studies, CAPEX estimates, RFP/RFQ documents and technical specifications.
Support preparation of AFE/business cases, project budgets and timelines.
Prepare technical & commercial comparison and evaluation of vendor quotations.
Assist Procurement in vendor selection, negotiation and purchase order finalization.
Track project expenditure against approved CAPEX.
Support reconciliation of actual project cost against approved budget.
Maintain project documentation including drawings, specifications, manuals, FAT/SAT reports, commissioning records and as-built documentation.
Support development and review of machine, equipment and plant layouts using AutoCAD or equivalent tools.
Ensure layouts consider productivity, material flow, ergonomics, safety, maintainability and future expansion.
Support development of electrical/control system architecture for automation projects.
Review electrical schematics, panel designs, instrumentation and control drawings.
Ensure all project activities are executed in accordance with company EHS standards.
Participate in preparation and implementation of: HIRA, FMEA, MOC, PSSR, Risk assessments, Pre-commissioning and commissioning safety checks.
Ensure contractor safety compliance at project sites.
Support statutory and regulatory compliance requirements associated with engineering projects.
Ensure machine safety requirements are incorporated into project design and execution.
Support all audit and plant preparation for documentation and aesthetic & 5S point of view.
Coordinate with IT/OT and regional cybersecurity teams for implementation of corporate cybersecurity requirements.
Ensure new PLCs, HMIs, SCADA, Windos, Software systems and connected equipment comply with applicable cybersecurity standards.
Support secure network architecture, user access control, backup and software management for automation systems.
Maintain appropriate backups of PLC programs, HMI applications and automation documentation.
Identify and evaluate suitable OEMs, automation vendors, contractors and system integrators.
Review vendor technical proposals and ensure compliance with project specifications.
Coordinate vendor activities during installation, testing and commissioning.
Monitor vendor performance on safety, quality, schedule and technical deliverables.
Develop strong working relationships with key technology and equipment suppliers.
Coordinate with Procurement and Finance teams for the complete procurement cycle for project-related equipment, services and materials.
Raise Purchase Requisitions (PRs) in Oracle ERP/ERP system as per approved project scope, specifications and budget.
Prepare technical specifications, scope of work, RFP/RFQ documents and commercial requirements for procurement.
Obtain and evaluate vendor quotations based on technical capability, quality, delivery, service and commercial competitiveness.
Prepare technical/commercial comparison statements and support vendor selection in accordance with company procurement procedures.
Coordinate with Procurement for Purchase Order (PO) creation, placement and amendments, wherever required.
Follow up with vendors and Procurement to ensure timely delivery of equipment, materials and services.
Coordinate with site teams and vendors for material receipt, inspection and GRN (Goods Receipt Note) completion.
Ensure timely submission and verification of vendor invoices against PO, GRN and agreed commercial terms.
Coordinate with Finance, Procurement and vendors for invoice processing, discrepancy resolution and payment release.
Monitor outstanding invoices and payments and ensure timely closure of vendor payment issues.
Maintain an up-to-date tracker for PR, PO, delivery, GRN, invoice and payment status.
Ensure procurement activities comply with approved project scope, company procurement policies and authorization requirements.
Monitor project expenditure against approved CAPEX/AFE budget throughout the project lifecycle.
Maintain project-wise budget trackers covering approved budget, committed cost, actual expenditure, forecast cost and balance available.
Identify potential cost overruns at an early stage and escalate deviations to the Project Manager/Engineering Manager.
Control project expenditure and ensure that commitments are made only against approved scope and budget.
Support cost-saving initiatives, value engineering and vendor negotiations without compromising safety, quality or project requirements.
Reconcile project costs with Finance and Procurement and ensure accurate closure of project financials.
Prepare monthly project cost reports highlighting Budget vs. Actual vs. Commitment vs. Forecast.
Ensure timely closure of open PRs, POs, GRNs, invoices and vendor payments at project completion.
Maintain complete procurement and commercial documentation for project audit and closure.
Support Maintenance and Engineering teams in improving equipment reliability, productivity and OEE.
Identify automation opportunities to reduce manual intervention, defects, downtime and operating costs.
Implement controls and automation improvements for existing equipment.
Support root-cause analysis of recurring machine and automation failures.
Develop standardization and continuous improvement initiatives across equipment and production lines.
Ensure completion of project punch points and technical documentation.
Conduct post-project review and capture lessons learned.
Ensure as-built drawings, PLC backups, software, manuals and spare-parts information are handed over to Maintenance.
Support post-commissioning performance audits.
Archive project documentation in accordance with company IMS requirements.
Ensure closure of all snag list from vendor end as well as commitment from Project team for internal action items listed during PSSR and handover of the projects.
Projects completed safely, on time and within approved CAPEX.
Successful commissioning and ramp-up of new equipment.
Reliable integration of automation and control systems.
Reduction in equipment downtime and manual intervention.
Improved machine productivity, OEE and process capability.
Compliance with EHS, quality, cybersecurity and engineering standards.
Complete and accurate project documentation.
Effective vendor and contractor performance management.