Sr. Controls Technician
Romeoville, IL

Onsite/Permanent

The Senior Controls Technician primary responsibility will maintain all the plant and production electrical and control systems, this includes electrical, pneumatic, hydraulic, mechanical and network sub-systems. Leadership position overseeing the installation, programming, and maintenance of various Programmable Logic Controller (PLC) systems, and related automation solutions, as well as supervising control techs across 3 facilities.
Inspecting, diagnosing, troubleshooting, repairing, and maintaining food processing and packaging equipment in a food manufacturing production environment.

Additionally, the Senior Controls Technician helps direct the modification and installation of control systems utilizing the Change Control process: Transfers knowledge of control systems and electrical projects; supports and maintains controls networks, web servers, data historian and operator interface systems. Secondary responsibilities include supporting Maintenance Supervisor & Manager on Capital projects by helping lead/execute the implementation of location projects, helping scheduling projects with the team junior techs from both plans.

Key concepts of the role include, but not limited to, developing controls concepts, program design, coding and implementation, instrumentation selection and operator interface development.
This position requires technical acumen, the ability for critical analysis, and attention to detail with an emphasis on strong computer skills.

Key Accountabilities

• This person is accountable to ensure, delivery and support for all plant control systems, following applicable company standards.
• Partner with other Maintenance Technician to resolve cross-functional problems.
• Use of available software systems to analyse and identify issues to drive throughout performance.
• Owner of the Plant Controls System.
• Supervise the work activities of outside contractors, control technicians, and other associates with the installation on instrumentation, PLC based control systems, and PC based operator interfaces.
• Prepare job aids, user documentation, systems documentation, standard operating procedures, and training materials for plant automation systems.
• Act as a technical resource to each location on controls related issues including troubleshooting, analysis and recommending practical corrective actions for control related problems.
• Use and follow all engineering standards when implementing projects.
• Constant communication with each production shift and maintenance teams to understand any breakdown or reliability issues.
• Achieve and maintain a high level of technical competency.
• Train and support non-technical users on the use of plant floor automation systems.
• Must demonstrate excellent trouble shooting skills to minimize equipment downtime with root cause analysis conducted to prevent re-occurrence.
• Knowledge of VFDs, PLCs, PLC programming on multiple platforms including RS Logix, Studio 5000, RS Linx, CompacLogix, and Factory Talk View programming.
• Knowledge of servo drives, motor controls, pneumatics, hydraulics, and power distribution.
• Work well under pressure in a fast-paced environment.
• Excellent verbal and written communication.
• Regular and predictable attendance.
• Must understand and comply with the company Allergen, Food Defense and HACCP policies.
• Must communicate with Supervision of any Food Safety and Equipment concerns.
• Use Personal Protective Equipment (PPE) as necessary for task at hand.
• Complete, legible, and accurate documentation.
• Excellent mechanical and safety aptitude.

Responsibilities

• Responsibilities include the technical development of the Controls Technicians at Romeoville & Chicago Heights.
• Responsible to train, supervise and to coordinate the efforts of the junior control technicians on all shifts and assist as necessary in troubleshooting and documentation of root cause failure analyses.
• Work directly with plant leadership to develop and execute projects involving continuous improvement, upgrades, and the resolution of re-occurring problems.
• Transfer knowledge to junior Techs team members to develop operating, troubleshooting procedures and repairs all manufacturing equipment such as wrappers, mixers, motors, conveyors, refrigeration systems.
• Identify opportunities and recommend changes to improve plant performance.
• Use and follow all engineering standards when implementing projects.
• Constant communication with each production shift and maintenance teams to understand any breakdown or reliability issues.
• Installs control and distribution apparatus such as switches, relays, and circuit-breakers panels.
• Performs preventive and corrective maintenance on the equipment. Monitors and ensures that the equipment is in excellent condition for operation.
• Repairs faulty equipment or systems. Visually inspects and tests machinery and equipment.
• Installs, programs, or repairs automated machinery and equipment such as robots and PLCs.
• Maintain current documentation of all electrical and controls systems including device hardware and software.
• Supervise controls technicians across 3 facilities.
• Create SOPs for troubleshooting machines, and upload them to BDA system, responsibility for machine reliability and meantime before failure.
• Lead programming and configuration efforts on PLC platforms (Allen Bradley preferred)
• Concept design for new PLC systems (centralized, decentralized, dual redundant, safety systems, etc.).
• Makes safety the number one priority. Keeps alert for safety issues and escalates immediately.
• Effectively prioritizes tasks based on department goals.
• Makes recommendations to continuously improve policies, methods, procedures, and/or products.
• Work from offsite locations occasionally to assist with equipment troubleshooting and repair.
• Maintain production equipment while running on a product production schedule.
• Perform electrical and mechanical inspection safely while equipment is in production.
• During equipment down days the Senior Controls Technician will coordinate work on the production lines taking care of any corrective, preventive or scheduled repairs in accordance with the company and/or machine vender specification.
• Complete assigned tasks in accordance with government codes and regulations, GMP, safety, quality control, company programs and procedures.
• Primarily performs preventive, scheduled or corrective repairs on batching and continuous process control systems, their networks, AC/DC and servo drives, pneumatics, hydraulics and mechanical components.
• To maintain an adequate level of critical components on hand ready to install/ preprogrammed PLC’s and touchscreens.
• Maintain work records in accordance with work orders, backlog, and job assignment system.
• May travel to various locations to purchase parts, attend training or for other duties.
• Works to maintain and improve on the quality, legality and safety of each product and the processes used in their manufacture.
• Responsible for keeping assigned work area clean and tidy at all times and reporting any potential contamination and suspicious activity to a Supervisor immediately.
• Any other duties as assigned.
• Help create and coordinate replacement solutions for obsolete components.

Skills, Experience & Qualifications

• CMMS

• Must utilize all safety devices, always comply with all safety policies and procedures.
• Must have skilled electrical skills for 24V – 480V.
• Must exhibit skilled trouble shooting skills using laptop of PLC, VFD, HMI operations
• Must be able to teach trouble shooting skills using laptop of PLC, VFD, HMI operations
• Must have ability to read and interpret schematics for process and instrumentation diagrams including Process &Instrument Drawings (PID), electrical single line drawings, instrument loop drawings, electrical cable, routing, and termination mechanical diagrams and machine layout drawings.
• Must be able to fully incorporate programs utilizing Factory talk View as well as software ladder logics.
• Must have the ability to upgrade obsolete PLC HMI and VFD’s with newest versions available.

Education, Technical Qualifications, Experience and Competencies Proficiency Level

Required

• Formal training in electrical or electronic engineering technology

Preferred

• Formal training in mechanical and/or plumbing techniques
• Experience in the food industry