Controls & Automation Supervisor

Purpose and role of job:

Responsible for managing and directing Controls Technicians, OEMs, and contractors across multiple shifts and work areas, providing electrical and controls in day-to-day work activities to support Operations. Also, identifying and implementing improvement programs in personnel skills, training, production equipment controls, processes, and preventative maintenance programs resulting in reduced manufacturing costs.

Principal Accountabilities/ Responsibilities:

• Observes all OSHA and company safety rules and uses the proper safety equipment at all times. Notifies Supervisor of potential electrical hazards and takes immediate corrective action.
• Follows necessary GMP regulations/guidelines.
• Works with Operations, Process Engineering, Maintenance and Controls Engineering and others to modify control systems including program modifications and wiring changes as needed.
• Works with equipment suppliers in support of modifications and installations of new equipment.
• Recruits, trains, administers, and directs all Controls Technicians personnel. Continually assesses personnel to ensure proper skills are developed and applied to support production requirements. Develops and applies any training programs to ensure skills are kept current.
• Applies knowledge of electrical controls, machinery controls, and components to provide technical direction for Project Engineers, OEMs, and vendors to design, install, interface, and start up new controls systems and equipment. This may include electrical component selection, machine acceptance testing, and start up problem solving.
• Works daily with Controls Engineering group to assist with upgrades of obsolete control components including PLCs, HMIs and Variable Frequency Drives.
• Ability to diagnose chronic control system issues and identify the root cause and best corrective action.
• Diagnoses problems using laptop computers interfaced to PLC’s, HMI’s and servo systems utilizing electrical schematics, meters, oscilloscopes, and any additional resources available.
• Tracks production performance, and conceives, develops, tests, and implements technical solutions for controls and automation problems. Develops and administers any annual preventative maintenance and inspection programs.
• Troubleshoots production utility equipment controls systems, components, and programs.
• Assists Production, Maintenance, and Engineers to meet daily priorities, coverage, and special projects.

• Oversees Controls support during machines installations and upgrades. Also, interfaces auxiliary equipment and identifies and corrects errors in programming and wiring.
• Ensures safe work practices are being followed, and violations are corrected immediately.
• Complies with FDA documentation and control requirements, including housekeeping, standard operating procedures, etc.
• Performs other duties as necessary when directed to do so.

Process Related
• Develops and documents process control characteristics for each production process.
• Understands manufacturing methods and the implications of design changes on production efficiency as well as quality.

Education and experience requirements:

• Bachelor’s degree in Electrical Engineering, Electronics, or equivalent.
• Solid knowledge of three phase, single phase and DC power.
• Familiar with NEC, NFPA-70E and standard wiring practices.
• Utilizes meters and oscilloscopes to identify electrical problems.
• Minimum of five years’ experience supervising in a high volume product environment requiring continuous support.
• Minimum of five years’ experience with industrial controls.
• Minimum of five years’ experience in a manufacturing industry.
• Advanced knowledge of all PLC based hardware and software.
• Advanced oral and written communication skills.
• Ability to apply advanced analytical concepts.
• Advanced leadership abilities.
• Standard knowledge of MS Word and MS Excel.
• Standard knowledge of work order software packages and spare parts inventory control.

Work Environment:

Work in an environment exposed to dust. Work in an environment exposed to marked changes in temperature or humidity. Observes all safety rules and uses the proper safety equipment at all times.

Physical Requirements:

• • Occasional sitting with frequent walking/standing during 8-hour shift.
  • Occasional bending, kneeling, climbing, and reaching overhead throughout shift.
  • Occasional pushing or pulling with the arms, legs, or body during shift.
  • Frequent lifting or carrying up to 10 pounds with occasional lifting or carrying up to 50 pounds.
  • Occasional repetitive use of hands.
  • Occasional light and firm grasping with hands throughout shift.