What are the responsibilities and job description for the Process Controls Engineer position at Samuel, Son & Co.?
Here are some of the great benefits that we offer:
- Competitive salary
- Company paid health and dental benefits
- Paid vacation and an annual bonus
- 401K with company match
- Opportunity for career stability and growth
- Tuition reimbursement program
- Protective personal equipment is provided or cost of purchase is reimbursed
- On the job training
Responsibilities and Duties
- Process improvement: Analyze existing workflows to identify and correct inefficiencies, reduce waste, increase output, and lower production costs.
- Implement advanced control strategies: Design and program advanced process control (APC) applications, including model predictive control (MPC) and multivariable control systems, to optimize production and improve product consistency.
- Apply Statistical Process Control (SPC): Utilize SPC techniques to monitor process behavior, identify non-random variations, and trigger corrective actions before defects occur. This includes designing and analyzing control charts to maintain statistical control.
- Provide floor presence and support: Spend significant time on the factory floor to oversee the implementation of control strategies, troubleshoot issues directly with maintenance and operations staff, and ensure automated systems are functioning correctly.
- Perform validation and documentation: Execute process qualification and continued process verification, developing comprehensive documentation to demonstrate consistent process performance in compliance with regulatory standards (e.g., FDA, ISO).
- Conduct data-driven analysis: Collect and analyze real-time process data from automated systems to identify trends, deviations, and opportunities for process optimization. Use data to drive improvement initiatives and root cause analysis.
- Project Management: Coordinate the full lifecycle of projects, including defining scope, managing timelines, selecting vendors, and commissioning new equipment and control systems
Required skills and qualifications
- Technical expertise: Demonstrated, hands-on experience with process control methodologies, including advanced control techniques, PID tuning, and SPC.
- Polymer Science: Understanding of plastic material (e.g. PP, PE, PET), along with understanding extrusion, injection molding, with a background on machine setup and tool design.
- Control systems proficiency: Deep knowledge of control systems, instrumentation, and relevant software, such as DCS, PLC, and SCADA systems.
- Robotics and automation: Proven experience in integrating, programming, and maintaining industrial robotic systems (e.g., FANUC, KUKA) for manufacturing applications.
- High technical aptitude: A natural inclination for hands-on problem-solving, with the ability to quickly grasp and master complex technical systems and diagnostics.
- Data analysis: Experience with CAD software (SolidWorks, AutoCAD), process simulation, modeling tools (e.g., MATLAB, Simulink), and data analysis software (e.g., Python, Minitab) to drive process improvements.
- Compliance and documentation: Strong understanding of quality management principles and the ability to produce detailed and accurate validation documentation.
Education and Certifications
- Preferred - Bachelor’s degree in chemical engineering, Mechanical Engineering, Industrial Engineering, or related field.
- Required - 3-5 years of experience within manufacturing, engineering, or process engineering roles.
- Strong knowledge of manufacturing processes, equipment, and materials.
- Proficiency in process simulation, modeling, and statistical analysis tools (e.g., MATLAB, Minitab, etc.), and Microsoft applications.
Work Environment
- Manufacturing environment works in a dynamic, hands-on setting, combining office-based analytical work with a heavy presence on the factory floor. The work environment is characterized by a blend of technical complexity, direct operational support, and a commitment to safety and quality.
- Factory floor: The role demands a significant presence on the production floor, where conditions can vary.
- Potential conditions: Expect variable temperatures, loud machinery, and the presence of industrial equipment.
- Safety protocols: Standard Personal Protective Equipment (PPE), such as hard hats, safety glasses, ear protection, and steel-toed boots, are typically required.
- Emergency response: You must be available to respond to emergency calls to address critical production issues or equipment failures.
- Collaboration: Interaction is frequent and essential, involving collaboration with cross-functional teams, including production managers, technicians, maintenance staff, quality assurance, and other engineers.
- Pace and demands: The environment is fast-paced and can be high-pressure, especially during new equipment commissioning, product launches, or major troubleshooting events. Success depends on strong problem-solving skills, resilience, and adaptability
SAMOMM
- Competitive salary
- Company paid health and dental benefits
- Paid vacation and an annual bonus
- 401K with company match
- Opportunity for career stability and growth
- Tuition reimbursement program
- Protective personal equipment is provided or cost of purchase is reimbursed
- On the job training
Responsibilities and Duties
- Process improvement: Analyze existing workflows to identify and correct inefficiencies, reduce waste, increase output, and lower production costs.
- Implement advanced control strategies: Design and program advanced process control (APC) applications, including model predictive control (MPC) and multivariable control systems, to optimize production and improve product consistency.
- Apply Statistical Process Control (SPC): Utilize SPC techniques to monitor process behavior, identify non-random variations, and trigger corrective actions before defects occur. This includes designing and analyzing control charts to maintain statistical control.
- Provide floor presence and support: Spend significant time on the factory floor to oversee the implementation of control strategies, troubleshoot issues directly with maintenance and operations staff, and ensure automated systems are functioning correctly.
- Perform validation and documentation: Execute process qualification and continued process verification, developing comprehensive documentation to demonstrate consistent process performance in compliance with regulatory standards (e.g., FDA, ISO).
- Conduct data-driven analysis: Collect and analyze real-time process data from automated systems to identify trends, deviations, and opportunities for process optimization. Use data to drive improvement initiatives and root cause analysis.
- Project Management: Coordinate the full lifecycle of projects, including defining scope, managing timelines, selecting vendors, and commissioning new equipment and control systems
Required skills and qualifications
- Technical expertise: Demonstrated, hands-on experience with process control methodologies, including advanced control techniques, PID tuning, and SPC.
- Polymer Science: Understanding of plastic material (e.g. PP, PE, PET), along with understanding extrusion, injection molding, with a background on machine setup and tool design.
- Control systems proficiency: Deep knowledge of control systems, instrumentation, and relevant software, such as DCS, PLC, and SCADA systems.
- Robotics and automation: Proven experience in integrating, programming, and maintaining industrial robotic systems (e.g., FANUC, KUKA) for manufacturing applications.
- High technical aptitude: A natural inclination for hands-on problem-solving, with the ability to quickly grasp and master complex technical systems and diagnostics.
- Data analysis: Experience with CAD software (SolidWorks, AutoCAD), process simulation, modeling tools (e.g., MATLAB, Simulink), and data analysis software (e.g., Python, Minitab) to drive process improvements.
- Compliance and documentation: Strong understanding of quality management principles and the ability to produce detailed and accurate validation documentation.
Education and Certifications
- Preferred - Bachelor’s degree in chemical engineering, Mechanical Engineering, Industrial Engineering, or related field.
- Required - 3-5 years of experience within manufacturing, engineering, or process engineering roles.
- Strong knowledge of manufacturing processes, equipment, and materials.
- Proficiency in process simulation, modeling, and statistical analysis tools (e.g., MATLAB, Minitab, etc.), and Microsoft applications.
Work Environment
- Manufacturing environment works in a dynamic, hands-on setting, combining office-based analytical work with a heavy presence on the factory floor. The work environment is characterized by a blend of technical complexity, direct operational support, and a commitment to safety and quality.
- Factory floor: The role demands a significant presence on the production floor, where conditions can vary.
- Potential conditions: Expect variable temperatures, loud machinery, and the presence of industrial equipment.
- Safety protocols: Standard Personal Protective Equipment (PPE), such as hard hats, safety glasses, ear protection, and steel-toed boots, are typically required.
- Emergency response: You must be available to respond to emergency calls to address critical production issues or equipment failures.
- Collaboration: Interaction is frequent and essential, involving collaboration with cross-functional teams, including production managers, technicians, maintenance staff, quality assurance, and other engineers.
- Pace and demands: The environment is fast-paced and can be high-pressure, especially during new equipment commissioning, product launches, or major troubleshooting events. Success depends on strong problem-solving skills, resilience, and adaptability
SAMOMM