Senior Automation Engineer

The Senior Automation Engineer leads automation initiatives that improve overall equipment effectiveness (OEE), reduce downtime, support compliance, and modernize factory systems. The Automation Engineer must possess extensive experience with programmable logic controllers (PLCs), human-machine interface/supervisory control and data acquisition (HMI/SCADA) systems, industrial networks, process controls, batch systems, and automation project execution in a regulated, over the counter (OTC) wellness product manufacturing facility.

Essential Duties and Responsibilities

· Design, program, troubleshoot, and maintain PLC systems, HMI/SCADA platforms, variable frequency drive (VFD) and servo systems, industrial instrumentation, batch control systems, and packaging automation systems.

· Support continuous manufacturing operations and rapid troubleshooting of production issues.

· Develop functional specifications, user requirement specifications, control narratives, and automation standards.

· Provide PLC and controls programming on typical platforms such as Rockwell, Allen-Bradley ControlLogix, CompactLogix, and  legacy systems such as the SLC 500 series.

· Provide programming and support of SCADA systems such as FactoryTalk, Wonderware, Ignition, DeltaV, or other distributed control systems (DCSs).

· Provide manufacturing support of automated systems, including mixing and blending, clean-in-place/sterilization-in-place (CIP/SIP) systems, filling and packaging lines, conveying systems, vision inspection systems, and environmental monitoring systems.

· Manage compliance and validation of computerized systems, ensuring compliance with FDA 21 CFR Part 11, cGMP requirements, HACCP and food safety standards.

· Support computerized system validation activities including installation, operational, and performance qualification (IQ/OQ/PQ) protocols, risk assessments, change control, and standard operating procedure (SOP) development.

· Provide internal plant production network support of ethernet/IP, OPC communications, managed industrial switches, and backup recovery systems.

· Manage automation capital projects from concept through commissioning.

· Coordinate vendors, integrators, contractors, and internal customers.

· Develop budgets, schedules, protocols, and commissioning plans.

· Perform hands-on adjustments, repairs, and replacements of motors, controls, and other electrical equipment.

· Provide technical training and education to all levels of the organization.

· Lead cross-functional improvement initiatives related to equipment automation.

· Develop, monitor, and communicate critical departmental key performance indicators (KPIs).

· Oversee corrective and preventive action plans (CAPAs), deviations, investigation reports (IRs), and audit action follow-ups.

· Support internal and external audits to support compliance.

Required Qualifications

Education & Experience:

· Bachelor's degree in engineering or related field.

· 7 years’ experience in industrial automation.

· Hands-on PLC programming experience with AB SLC500, AB ControlLogix, and AB Panel View HMI.

· Industrial instrumentation and closed-loop controls troubleshooting experience.

· Experience with motion control, including variable frequency drives, stepper motors, and servo systems.

· Experience with SCADA/HMI configuration, process instrumentation, motion control, batch systems, industrial networking, SQL/database, MES integration, historian systems.

Knowledge, Skills, & Abilities (KSAs):

· Strong knowledge of Occupational Safety and Health Regulations, Machinery and Building Codes in an industrial environment. Understanding of NEC, OSHA, GMP, and other safety requirements. Ability to understand, comply with and apply the National Electric Code (NEC) in an industrial setting.

· Knowledge of methods and techniques of installation, maintenance, and repair related to electrical equipment and facilities.

· Ability to develop and implement a preventative maintenance plan for all electrical and electronic equipment.

· Ability to use common precision measuring instruments, gauges, and hand tools.

· Ability to work under pressure in a fast-paced manufacturing environment.

· Proficiency with Microsoft Word, SharePoint, Excel, and Outlook.

· Ability to apply critical thinking in problem solving. Must be able to demonstrate practical problem solving and trouble shooting skills. Ability to demonstrate practical problem solving and trouble shooting skills. Ability to define problems, collect data, establish facts, and draw valid conclusions. Ability to interpret an extensive variety of technical instructions in mathematical or diagram form and deal with several abstract and concrete variables.

· Strong communication, organization, and prioritization skills. Must have the ability to communicate effectively, both verbally and in writing, with internal staff and management. Ability to read, analyze, and interpret general business periodicals, professional journals, technical procedures, or governmental regulations. Ability to write reports, business correspondence, and procedure manuals. Ability to effectively present information and respond to questions from groups of managers, clients, customers, and the general public.

· Ability to work with mathematical concepts such as probability and statistical inference, and fundamentals of plane and solid geometry and trigonometry. Ability to apply concepts such as fractions, percentages, ratios, and proportions to practical situations.

Preferred Qualifications

· Knowledge of CFR Part 211 cGMP regulations as applicable to engineering.

· Electrical license in the state of North Carolina.