Process Control Engineer

Detailed Job Description:

General Information:

• The individual will play an important role in project rollouts and plant support by providing electrical programming and robotics support at the plant level. They will also implement automation solutions for various processes.
• This person will be responsible for responding to plant support requests as needed and providing in-depth technical guidance and design support for both new and existing automation solutions.

Non-Negotiable Required Skills:

• Project management experience
• Electrical robotics and/or PLC experience
• Strong communication skills
• Self-driven and able to work independently
• Bachelor s degree in engineering (mandatory)
• Team player

Why is this position available?

• The team currently consists of several engineers, but they have more projects and plant support responsibilities than the current headcount can manage.
• Some team members have strong PLC expertise, while others specialize in robotics. However, there is a skills gap on the electrical and electrical robotics side, which this role is intended to fill.

Location & Travel:

The ideal candidate will be local to the Fort Mill location. Is travel involved?

• Yes, there will be limited travel to interior plants across North America.
• Approximately 90% of the individual's time will be spent at the Fort Mill location.

Extension or Conversion After 6 Months

• This will depend on business needs at that time.
• If an appropriate full-time position becomes available, they may consider converting the contractor into that role. However, this is entirely dependent on future openings.

Interview Process

• The first interview will be conducted via Microsoft Teams.
• If the candidate is successful, they will be invited for an onsite interview at the plant.

Expert in PLC programming with the ability to adapt and convert programs across different PLC platforms. Experience with Fanuc robotics and Allen-Bradley PLC controls. They can use FactoryTalk and Allen-Bradley software for programming, troubleshooting, and automation support.

Purpose Of the Job

• This role is responsible for developing new manufacturing processes and overseeing Controls and Automation workstreams within capital projects. It ensures that automation strategies are properly designed, integrated, and executed to drive operational improvements. Key responsibilities include eliminating or reengineering manual tasks, advancing future of work initiatives, and enabling safer, more efficient, and more reliable production operations. Typical duties involve defining new application requirements, updating existing applications based on functional needs, conducting cost benefit analyses, and prototyping, designing, integrating, and testing robotic and automation systems.
• The main responsibility is to execute Automation initiatives with operations teams to eliminate 3Ds (Dirty, Dull and Dangerous tasks) and improve Safety, Quality and Productivity through Automation and process stability. The successful candidate works closely with plant operations teams by leveraging team resources and guiding plant technical teams to achieve site goals. This role also collaborates with the Process SME Engineers, OC IT, Capital Team, R&D Team, and Quality Team as well as Site Operations to enhance manufacturing processes leading to quality Door products.

REPORTS TO: This position reports to the Process Development Manager.

TRAVEL: 40-50% typical, as needed.

SPAN OF CONTROL: This position has no direct reports. This role is also expected to provide support and coaching to Process and Technical teams and the site subject matter experts across the division.

REGION: This position will support 4-6 plants in Doors Division.

LOCATION: Continue to work in assigned location/plant. Remote on travel weeks.

JOB RESPONSIBILITIES

Safety

• Ensure a safe work environment through employee coaching and engagement
• Effectively communicates Safety Stand with external contractors/parties and ensures that they work according to our safety standards
• Ensure all the processes /automation are adhered to OC Safety Standards.
• Leads by example through hazard recognition and elimination.

Process Automation and Optimization

• Provide support to sites with a customer centric approach by collaborating with Plant teams and work on developing process/ Automation projects that will eliminate Dull, Dangerous and Dirty tasks.
• Collaborate with Process SME Engineers in identifying process needs and process limits and design process/automation meeting those Process Specs.
• Design and implement automated systems, including robotics, PLCs, and control systems.
• Develop and maintain standards for automation architecture, programming, and documentation.
• Collaborate with operations, IT, and quality teams to identify automation opportunities and deliver cost-effective solutions.
• Manage project timelines, budgets, and resources to ensure successful execution.
• Ensure compliance with safety, regulatory, and cybersecurity requirements for automated systems.
• Facilitate engagement with capital engineering, IT, Productivity, reliability and Quality Teams and ensure projects and goals are being met. Remove roadblocks and re-assign resources as needed. Guide team members in analyzing process data and providing feedback to plants to optimize performance.
• Ensure effective use of new process technologies (Digital Manufacturing) in Doors operations. Promote networking between plants, R&D, and other groups to identify and implement best practices.
• Implements root-cause analysis and corrective actions for issues surfaced through losses in Automation, leveraging digital tools

Support Design and Commissioning of Capital & Productivity Projects

• Identifies and implements equipment improvements, working directly with the Capital Engineering team and Productivity team as needed
• Uses a comprehensive Management of Change process on projects with Lessons Learned after completion of projects
• Ensures that preventative and predictive plans, work instructions, and other procedures related to the installation, maintenance and repair of plant equipment and machinery are built and executed
• Aids in the development and implementation of the Doors capital plan, Doors site improvement plans, and Doors process stability plan
• Commissions and supports project startup as the technical and process resource when applicable, working directly with plant and Capital engineering teams
• Coaching and Consulting
• Executes training plans for plant Operations/Maint/Technical Leaders and creates a continuous learning environment for employees
• Trains and directs the work of skilled craft people in advanced process control understanding
• Documents knowledge into knowledge repository, and shares knowledge with key personnel and stakeholders
• Other work/responsibilities as directed by plant leadership, operations team, or Division

JOB REQUIREMENTS

MINIMUM QUALIFICATIONS

• Bachelor s degree in electrical engineering, Mechanical Engineering, Automation, or related field.
• Experience in industrial automation, robotics, and control systems integration
• Minimum of 3 years experience within a manufacturing or technical environment; heavy manufacturing in a Discrete operation or Doors industry highly preferred. Additional 4 years of experience in lieu of engineering degree.
• Knowledge of PLC programming, SCADA systems, and industrial networking.
• Familiarity with Lean manufacturing principles, TPM and process optimization.
• Proficiency in automation software and tools (e.g., Rockwell, Siemens, Python for scripting).
• Strong analytical and problem-solving skills.
• Effective communication and collaboration skills across technical and non-technical teams.
• Ability to lead complex automation projects from concept to implementation.
• Ability to adapt to emerging technologies and changing business needs.
• Ability to manage multiple priorities and deliver results under tight deadlines.
• Certification in Six Sigma (Green Belt) preferred

Knowledge, Skills and Abilities

• Ability to analyze and use data to drive sustainable equipment improvements
• Ability to effectively manage multiple priorities or projects at one time
• Ability to influence without authority
• Can use data effectively to establish concrete Return on Investment (ROI) of suggestions
• Experience working in a cross functional team environment and effectively transfer knowledge at all levels through effective communication skills
• Experience with project management; understanding internal and external needs
• Computer and Software competencies; skills in Braincube, and Aspentech preferred
• Knowledge and experience with Root Cause Analysis, failure modes effects and analysis, and other Total Productive Maintenance activities preferred