Controls Engineer

Refresco

11d

About The Position

Reporting to the Senior Manager of Controls Engineering, the Controls Engineer will lead continuous improvement initiatives and oversee infrastructure automation upgrades to modernize systems and address obsolescence. This role requires expertise in PLC, HMI, SCADA, VFD, and servo system programming and troubleshooting, as well as proficiency in Ethernet network configuration, diagnostics, and SQL Server development. Additionally, the Controls Engineer will focus on enhancing the technical capabilities of Controls Technicians, Electricians, and Instrumentation Technicians by creating comprehensive training plans and delivering targeted, skill-building training.

Requirements

Ability to establish, meet deadlines and prioritize work.
Demonstrated problem solving skills.
Ability to initiate, compile, analyze and provide accurate reporting.
Must be confident, approachable, and energetic with an eye for detail.
Proficiency in Microsoft Word, Excel, PowerPoint.
Work with confidential information.
Excellent interpersonal skills, both verbal and written.
Diploma or degree in Electronics, Automation, Electrical Engineering, or equivalent experience.
Rockwell Automation or equivalent PLC, VFD, HMI, and Servo System programming and troubleshooting expert.
PLC programming utilizing RS Logix 5, 500, 5000, and FactoryTalk Studio software.
Device Net and Ethernet I/P knowledge will be key for success.
Remote communication and I/O systems experience.
Experience in Virtual Network and Thin Clients.

Nice To Haves

SQL Server Experience preferred.
Licensed Industrial Electrician preferred.
Experience in food processing, bottling and packaging preferred.

Responsibilities

Utilizes expert knowledge of PLCs, HMIs, Ethernet Networks, I/O networks, to efficiently troubleshoot controls automation system issues, determine root cause, and implement timely, permanent solutions.
Use condition monitoring tools to perform predictive maintenance (PdM) analysis on Production Equipment to identify pending maintenance issues, and issue PM work orders to take corrective action to prevent emergency breakdowns and to determine root cause of maintenance issues.
Analyze performance trends and conducts root cause corrective action to drive improvements.
Drive continuous improvement opportunities to improve plant performance and machine reliability.
Promote infrastructure automation upgrades and establish automation disaster recovery strategy.
Lead team of electricians and develop training plans to improve the team’s skillset.
Develop improvement processes to reduce scrap and defects, enhance throughput, and implement SOPs and Best Practices using engineering techniques (e.g., Process Flow Design, FMEA, Time Study, Poke Yoke).
Coordinate the installation of new equipment to optimize production efficiency and reliability.
Act as a project engineer; research applicable codes, regulations and requirements for the assigned projects; develop and oversee the development of construction plans and specifications; oversee and prepare changes as conditions warrant.
Maintain a knowledge base in the capacity of existing utilities and the current level of utilization.
Ensure compliance with safety, environmental, and regulatory standards by maintaining current knowledge, preparing reports, and adhering to all applicable codes.
Maintain constant awareness of progress on assigned projects to ensure compliance with designated time and cost schedules for project completion; supervise and participate in the inspection of construction projects; prepare change orders; review contractor’s estimates and prepare/review progress payments.
Leads capital projects supporting new processes, bottling lines, utilities, and facility management to enhance operational efficiency across Refresco’ s US facilities.
Designs, implements and tunes processing, batching, thermal processing, refrigeration, bottling, CIP & utility control systems, evaluates alternatives, selects & sizes hardware, develops estimates, and ensures regulatory compliance.
Collaborates with OEM vendors to implement control schemes optimizing line performance for various products and packaging formats.
Develops P&IDs, PID loops, ladder diagrams, pin charts, panel layouts, and wiring diagrams; sizes equipment & components; prepares construction packages; manages construction; and controls schedule and cost within project timeline and budget.
Maintains company drawings and technical records and provides clear and concise analysis and reporting.
Initiates appropriation requests, purchase orders, and contracts as required.
Identifies opportunities to improve plant performance, product quality, and employee welfare, while leading solution development and participating in capital planning.
Provides technical support for the operation, maintenance and improvement of processing equipment, production lines, utilities, and buildings.
Works in a team environment to support company objectives, initiatives and policies.
Improves production line performance using Controls Automation and Continuous Improvement expertise.

Benefits

Medical/Dental/Vision Insurance
Health Savings Accounts and Flexible Spending Accounts
Life and AD&D Insurance, critical illness, hospital indemnity, and accident insurance
Short-term disability and long-term disability
Pet Insurance
Legal Benefits
401(k) Savings Plan with Company Match
12 Paid Holidays
Vacation Days and Paid Sick Time Off
Well-being Benefit
Discount and Total Reward Programs