Tower Warehouse Automation Process Controller

PepsiCo•Claymont, DE

41d

About The Position

As a Tower Process Controller, you’ll serve as the nerve center of our automated warehouse operation — managing complex systems, solving problems on the fly, and guiding your team to consistently meet production goals. You will gain Leadership experience while working with advanced automation that is shaping the future of distribution. The Tower Process Controller oversees the automated case-picking system, ensuring safe, accurate, and efficient production. This role requires a comprehensive understanding of automation picking software and conveyor/palletizer operations. The Tower Process Controller is responsible for coordinating production flow, troubleshooting issues, supporting other process controllers, and ensuring that customer orders are processed and released on time. Tower Process Controllers are accountable for overall system performance — driving closure of downtime events, proactively identifying potential rate loss areas, and implementing corrective actions. They serve as the central link between other process controllers, maintenance, and management to ensure that customer orders are fulfilled on time and system throughput targets are achieved.

Requirements

High school diploma or equivalent; associate or bachelor’s degree preferred.
At least 2 years of previous production line or automation experience in a manufacturing or warehousing industry (preferably bottling or food) are preferred.
Demonstrated Towership ability with experience directing teams.
Strong troubleshooting and problem-solving skills under time-sensitive conditions.
Effective communication skills, with ability to coordinate across multiple departments.
Computer proficiency and ability to navigate production software.
Regular, reliable, predictable attendance.
Must be analytical, technologically competent, and mechanically inclined.
Must be able to sufficiently read, write and speak English due to the safety sensitivity of this role.
Possess good oral and written communication, analytical, and mechanical skills.
Interested individuals must be able to work any shift, 7-day work week, and have a stable work history.
Experience with pallets and pallet handling (e.g., operating a forklift, stacking/bundling product, etc.).

Nice To Haves

Experience with high-speed machinery and equipment (e.g., high output, high performance equipment, fast paced production environment, warehouse automation environment, etc.).
Experience with computers in a manufacturing setting (e.g., electronic settings, machine speed, gauge pressures, basic troubleshooting, solving faults/alarms, and resetting equipment, etc.).
Experience with sanitization (e.g., basic procedures/steps, food safety practices, identifying risks).

Responsibilities

EQUIPMENT OPERATION & MAINTENANCE:
Perform an initial inspection of equipment at the start of each shift.
Perform preventative, predictive, and autonomous maintenance on equipment as required.
Know, understand, and complete all centerlines (CL) and clean, inspect, and lubrication (CIL) points for all equipment each shift.
Keep machines loaded with materials, troubleshoot and address equipment stop conditions when needed, expediting repairs by working closely with maintenance.
Adjust equipment settings as required to optimize efficiency and maximize case output.
Oversee equipment status, troubleshoot stoppages, and ensure system balance.
QUALITY, SANITATION & SAFETY:
Perform necessary sanitation and quality assurance checks; ensure equipment and tanks are clean and free of debris/foreign objects.
Ensure finished product and completed pallet quality.
Maintain a clean work area through good housekeeping practices and adherence to safety standards.
Ensure compliance with all safety procedures, including proper use of EMOs, lockout/tagout, and conveyor safety practices.
DOCUMENTATION & REPORTING:
Maintain records/logs and complete all paperwork/documentation associated with start-up, operation (including downtime), and shut-down activities.
SYSTEM & ORDER MANAGEMENT:
Operate and manage automation system inventory and customer orders.
Process and release routes and resolve sequence issues.
Make real-time operational decisions regarding truck assignments, routing, out-of-stock product, and order prioritization.
TOWERERSHIP & TRAINING:
Supervise overall case-picking operations, directing staff across picking, palletizing, and handstack functions.
Train operators in safe, efficient system operation, including equipment resets, sequence recovery, and order processing.
Communicate with cross-functional teams to resolve operational issues and escalate when necessary.

Benefits

Paid time off subject to eligibility, including paid parental leave, vacation, sick, and bereavement.
In addition to salary, PepsiCo offers a comprehensive benefits package to support our employees and their families, subject to elections and eligibility: Medical, Dental, Vision, Disability, Health, and Dependent Care Reimbursement Accounts, Employee Assistance Program (EAP), Insurance (Accident, Group Legal, Life), Defined Contribution Retirement Plan.

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