Operational Technology Engineer

Merck•Kankakee, IL

1d•Onsite

About The Position

As the Operational Technology Engineer, you are responsible for the design, implementation, maintenance, and continuous improvement of automated control systems across our manufacturing operations. Serving as the subject matter expert (SME) for all automation and control activities, you will collaborate closely with production, maintenance, process engineering, and safety teams to ensure the reliable, efficient, and safe operation of all automated equipment. This is an on-site, hands-on engineering role that requires both deep technical expertise and strong collaborative skills. The position is based out of Kankakee, Illinois and will support our production site in Urbana, Illinois as needed (twice per month). Travel may be required up to 20% of the time.

Requirements

Bachelor’s Degree in Engineering (Electrical, Control Systems, Mechatronics, etc.)
2+ years of hands-on experience in an industrial manufacturing or process environment
2+ years experience programming and commissioning Allen-Bradley (Rockwell Automation) and/or Siemens PLCs
1+ years experience working with HMI/SCADA platforms such as FactoryTalk View, Ignition, WinCC, or equivalent
1+ years experience working with industrial networking including Ethernet/IP, Profinet, Modbus TCP, and DeviceNet

Nice To Haves

Ability to troubleshoot complex automated systems under pressure
Strong understanding of electrical control panel design and the ability to read and interpret electrical drawings
Experience with DCS platforms such as Emerson DeltaV, Honeywell Experion, or ABB 800xA
Experience with building automation systems i.e. METESYS, Automated Logic
Familiarity with functional safety lifecycle processes and IEC 61511 / IEC 62061
Knowledge of ISA-18.2 alarm management methodology
Experience with IIoT platforms, data historians (OSIsoft PI, Wonderware), or MES integration
Exposure to Lean Manufacturing or Six Sigma methodologies
TÜV Functional Safety Engineer certification is an advantage
Experience working in a regulated manufacturing environment such as food and beverage, pharmaceutical, or chemical processing

Responsibilities

Design, develop, commission, and test PLC, DCS, HMI, and SCADA systems for new and existing production equipment.
Create and maintain detailed system documentation, including electrical schematics, network architecture diagrams, I/O lists, and functional design specifications.
Collaborate with equipment vendors and system integrators to ensure designs meet site standards, project requirements, and corporate data integrity policies.
Lead Factory Acceptance Testing (FAT) and Site Acceptance Testing (SAT) for new installations.
Provide first-line technical support for control system faults, alarms, and unexpected production downtime events.
Diagnose and resolve complex electrical and controls-related issues quickly to minimize operational disruption.
Provide daily oversight of site automation to ensure reliable operations and establish clear escalation paths for critical issues.
Analyze alarm data, downtime trends, and system performance metrics to identify and eliminate recurring root-cause issues.
Develop and maintain practical fault-finding guides and troubleshooting documentation for the maintenance team.
Identify and champion opportunities to improve Overall Equipment Effectiveness (OEE) through control system enhancements.
Lead, execute, and support capital improvement projects from initial scope definition through commissioning and final handover.
Implement alarm management strategies (aligned with ISA-18.2 standards) to reduce nuisance alarms and improve operator effectiveness.
Drive the standardization of control system hardware, software platforms, and programming practices across the site.
Evaluate and introduce emerging technologies, including advanced process control, data analytics, and IIoT integration.
Maintain the integrity and security of the Industrial Control System (ICS) network.
Implement and enforce cybersecurity best practices in line with IEC 62443 standards and company policy.
Manage control system patching, regular backups, and disaster recovery procedures.
Partner with the IT department to ensure appropriate, secure segmentation between OT (Operational Technology) and IT networks.
Control, monitor, and audit remote access to production control systems.
Ensure all control system designs and modifications comply with functional safety standards (including IEC 61511 and IEC 62061).
Participate in HAZOP, Risk Assessments, and System Integrity Level (SIL) studies; implement required Safety Instrumented Functions (SIFs).
Maintain and test Safety Instrumented Systems (SIS) in accordance with the site’s safety lifecycle plan.
Manage all control systems changes strictly through the site’s Management of Change (MOC) process and maintain version control for all program files.
Update Standard Operating Procedures (SOPs), as-built documentation, and training records following any system modifications.
Ensure all work complies with site electrical safety rules, lockout/tagout (LOTO) procedures, and work permit systems.