Job Specification: PLC Engineer

Job Summary:

The Mid-Level PLC Engineer is responsible for designing, programming, troubleshooting, and maintaining PLC-based control systems in industrial, commercial, and manufacturing environments. This role involves working on complex automation systems, providing technical expertise, and optimizing PLC systems for operational efficiency. The engineer will collaborate with senior engineers and cross-functional teams to implement control systems, enhance system performance, and troubleshoot advanced system issues. This role also includes mentoring junior engineers and ensuring systems comply with safety, quality, and regulatory standards.

Key Responsibilities:

1. PLC Programming and System Design:

   • Design and develop PLC programs for automation processes, ensuring they meet project specifications, functional requirements, and industry standards.
   • Develop and configure control strategies for PLCs using advanced programming languages (e.g., Ladder Logic, Structured Text, Function Block Diagram).
   • Create system layouts, wiring diagrams, and control panel designs for automation projects.
   • Review and refine existing PLC programs, optimizing them for better performance and efficiency.

2. System Integration and Configuration:

   • Integrate PLC systems with other automation components, including SCADA, HMI, sensors, actuators, and control panels.
   • Ensure seamless communication between PLCs and other industrial control systems, including troubleshooting and resolving communication issues.
   • Assist in configuring HMI/SCADA systems to monitor, control, and automate processes effectively.

3. Project Management and Execution:

   • Manage and execute automation projects, including system design, programming, testing, installation, and commissioning.
   • Coordinate with other engineering teams (e.g., electrical, mechanical, instrumentation) to ensure smooth integration of automation systems with other systems and equipment.
   • Ensure projects are completed on time, within budget, and to required quality standards.
   • Prepare and maintain project documentation, including system specifications, reports, and installation manuals.

4. Troubleshooting and Optimization:

   • Troubleshoot complex issues in PLC-based systems, control panels, sensors, and automation components.
   • Perform root cause analysis and implement corrective actions to resolve system faults, minimizing downtime and ensuring operational continuity.
   • Lead efforts to optimize PLC programming and control systems to enhance efficiency, reduce energy consumption, and improve performance.

5. System Maintenance and Support:

   • Perform preventive maintenance and calibration of PLC systems to ensure optimal performance.
   • Lead system upgrades, ensuring the continued reliability of PLC-based control systems.
   • Provide technical support for PLC systems during both routine operations and emergency situations.
   • Mentor and train junior engineers and technicians on PLC programming, troubleshooting, and system maintenance best practices.

6. Safety and Compliance:

   • Ensure all PLC programming and control system designs comply with industry safety standards, electrical codes (e.g., NEC, IEC), and regulatory requirements (e.g., OSHA).
   • Implement safety protocols, including lock-out/tag-out procedures, to ensure safe operation of PLC systems.
   • Conduct safety audits and risk assessments to ensure that control systems meet internal and external safety standards.

7. Documentation and Reporting:

   • Maintain accurate records of all PLC programming, system modifications, troubleshooting, and maintenance activities.
   • Prepare detailed reports on project progress, system performance, and troubleshooting actions taken for internal teams and clients.
   • Update and maintain system documentation, including control system drawings, wiring diagrams, and process flow charts.

8. Collaboration and Cross-Functional Coordination:

   • Work closely with other engineers, project managers, and technical teams to ensure alignment of PLC-based systems with operational and business goals.
   • Coordinate with external contractors, vendors, and clients to ensure that all system requirements are met and that project milestones are achieved.
   • Communicate effectively with stakeholders, providing technical advice and status updates as necessary.

Skills and Knowledge Required:

• Advanced knowledge of PLC programming (e.g., Ladder Logic, Structured Text, Function Block Diagram), control systems, and automation technologies.
• Strong experience in troubleshooting, debugging, and optimizing PLC systems, including hardware and software components.
• Knowledge of industrial control systems, including sensors, actuators, motor controls, and communication protocols (e.g., Modbus, Profibus, Ethernet/IP).
• Experience with SCADA systems and HMI development for monitoring and controlling automation systems.
• Strong understanding of electrical safety standards and regulations (e.g., NEC, IEC, OSHA).
• Excellent problem-solving and analytical skills, with the ability to quickly diagnose and resolve complex control system issues.
• Experience in managing and executing automation projects, including planning, design, programming, and commissioning.
• Ability to work collaboratively in a team environment and mentor junior engineers.
• Strong written and verbal communication skills to document work and communicate with clients, project managers, and other engineers.

Educational Qualifications:

• Bachelor’s degree in Electrical Engineering, Control Systems Engineering, Electronics Engineering, or a related technical field.
• Certifications in PLC programming, industrial automation, control systems, or related fields (e.g., Siemens, Rockwell) are highly desirable.

Experience:

• 3-5 years of experience in PLC programming, control systems engineering, and industrial automation.
• Experience in troubleshooting, optimizing, and maintaining PLC-based control systems in industrial or manufacturing environments.
• Hands-on experience with SCADA and HMI systems, PLC hardware, and industrial networking protocols.

Tools and Technologies:

• Proficiency with PLC programming software (e.g., Siemens TIA Portal, Rockwell Studio 5000, Allen-Bradley).
• Experience with SCADA software (e.g., Wonderware, Ignition, Siemens WinCC) and HMI development tools.
• Familiarity with electrical design software and simulation tools (e.g., AutoCAD, MATLAB, LabVIEW).
• Knowledge of industrial communication networks and protocols (e.g., Modbus, Profibus, Ethernet/IP).

Other Requirements:

• Strong organizational skills with the ability to manage multiple projects and deadlines simultaneously.
• Ability to lead projects and work independently while coordinating with cross-functional teams.
• Willingness to travel to project sites, client meetings, and vendor locations as required.
• A proactive approach to problem-solving, continuous improvement, and professional development.