Process Automation Engineer

SUMMARY

The Process Automation Engineer – Berkeley Facility designs, optimizes, and supports automated systems to improve production line efficiency, equipment reliability, and product consistency across Whitsons' Culinary Services manufacturing environment. This role drives operational performance by implementing advanced automation technologies, enhancing line throughput, reducing downtime, and ensuring seamless integration of equipment and controls. The engineer collaborates with cross-functional teams to support continuous improvement, food safety, and scalable manufacturing processes.

ESSENTIAL FUNCTIONS, RESPONSIBILITIES AND DUTIES

Automation & Process Control Integration

• Design, program, troubleshoot, and optimize PLC, HMI, SCADA, MES, and automated control systems.
• Implement automation solutions including robotics, smart sensors, vision systems, automated batching, and conveyor controls.
• Ensure integration with plant digital systems, interlocks, alarms, traceability tools, and data platforms.
• Lead commissioning of new automation equipment, upgrades, and modifications.

Production Line Optimization

• Conduct line studies to improve throughput, cycle times, and OEE.
• Reconfigure line layouts to eliminate bottlenecks and strengthen flow, ergonomics, and efficiency.
• Optimize mixing, cooking, seasoning, packaging, and conveyor processes using engineering and Lean methodologies.
• Collaborate with operations on planning and execution of new lines, expansions, and automation enhancements.

Continuous Improvement & Lean Manufacturing

• Lead CI initiatives (Kaizen, 5S, SMED, RCA, TPM) to improve reliability and reduce scrap, rework, and downtime.
• Identify systemic issues and implement standardized processes and improvements.
• Analyze equipment data to drive predictive maintenance and technology upgrades.

Equipment Integration, Troubleshooting & Support

• Partner with Maintenance to diagnose automation and electromechanical issues.
• Support equipment selection and ensure compatibility with automation and integration requirements.
• Develop equipment lifecycle strategies including upgrades and modernization plans.

Data Intelligence, Reporting & Digital Transformation

• Build real-time dashboards to monitor OEE, downtime, yields, throughput, and performance KPIs.
• Integrate automation systems with ERP/MES platforms for improved data visibility.
• Use analytics to support decision-making and identify continuous improvement opportunities.

Food Safety, Compliance & Quality Support

• Ensure automated processes comply with USDA, HACCP, GMP, and sanitation requirements.
• Validate changes to automated processes for safety, quality, and critical control points.
• Troubleshoot quality deviations caused by automation and implement corrective actions.

Project Management & Cross-Functional Collaboration

• Lead automation and engineering projects from concept to implementation.
• Develop project scopes, budgets, timelines, and communication plans.
• Collaborate with Culinary, R&D, QA, Production, Logistics, and Facilities to support new products and process changes.

Additional Duties

• Train operators, supervisors, and maintenance teams on automation systems.
• Support emergency response for critical system failures.
• Participate in facility expansion initiatives, pilots, and strategic projects.
• Perform other duties as assigned.

This role offers a salary range of $105,000 – $125,000 annually, based on skills, experience, and location. Employees also receive a comprehensive benefits package including health, dental, vision, 401(k) with company match, generous PTO, and paid holidays.

Requirements:

REQUIRED QUALIFICATIONS AND COMPETENCIES

Education

• Bachelor's degree in Electrical, Mechanical, Industrial, Automation Engineering, Mechatronics, or related field required.
• Professional certifications preferred (Rockwell/Siemens, ISA, robotics, controls engineering).

Experience

• 3–7 years in automation or process engineering within high-volume manufacturing.
• Food, beverage, pharma, or protein manufacturing experience highly preferred.
• Demonstrated experience optimizing production lines and commissioning equipment.

Technical Skills

• Proficiency in PLC programming (Allen-Bradley, Siemens), HMI design, SCADA, MES.
• Strong knowledge of robotics, conveyors, PID loops, sensors, instrumentation, and industrial controls.
• Ability to read schematics, P&IDs, and technical engineering documentation.
• Experience with data systems, OEE tools, and digital integration platforms.

Core Competencies

• Production Line Optimization
• Automation Engineering & Controls
• Problem Solving & Root Cause Analysis
• Continuous Improvement & Lean
• Project Management
• Cross-Functional Collaboration
• Innovation & Systems Thinking
• Safety & Quality Mindset

Salary : $105,000 - $125,000