Senior Automation Controls Engineer at AZEK

Position Summary: 

AZEK is seeking a Principal Automation Engineer (Senior Automation Engineer) to assist as a technical resource for teams of highly skilled engineers responsible for maintaining business critical equipment and infrastructure and bringing in new processes, equipment, and improvements.  The initial focus will be on expanding our technical and project support to reduce risk to the operation while supporting capital, CI, R&D, IT, Quality, and Process projects as a technical resource and safeguard.  

ESSENTIAL FUNCTIONS

• Act as a technical leader/subject matter expert. This includes hands-on activities to keep operations running smoothly when there is a skills gap with a primary focus on new processes, projects, and methods. This also includes training and exposing less experienced employees to these required skills (Server work, in-the-field reprogramming, new automation processes)
• Act as the company lead on manufacturing digitalization strategy and deployment, with an ability to step in and complete high level technical tasks to advance the company’s position.
• Implement and recommend automation engineering strategies that align with the company's goals and objectives.
• Oversee the design, development, and implementation of control systems for new and existing equipment, ensuring that they meet safety and performance standards.
• Adjust and develop performance and safety standards as the company grows.
• Develop and manage project timelines and budgets, ensuring that projects are completed on time and within budget.
• Collaborate with other departments, such as production, maintenance, and quality assurance, to ensure that controls engineering projects meet their needs.
• Ensure compliance with safety standards and regulations, such as OSHA and NFPA, in all controls engineering projects.
• Develop and maintain relationships with vendors and suppliers, negotiate contracts and managing relationships to ensure the best possible pricing and service.
• Communicate effectively with management and other departments to ensure that controls engineering projects are aligned with the company's overall goals and objectives.
• Participate in implementing standardization, process improvement, and cost reduction programs.
• Lead efforts to increase equipment OEE (Overall Equipment Effectiveness) through controls engineering optimization and automation.
• Develop and implement cybersecurity policies, procedures, and standards for OT systems.
• Development of capital plans to complete upgrades, close out cybersecurity issues, and remediate process bottlenecks.
• Perform regular risk assessments and vulnerability assessments on OT systems and infrastructure.
• Define and ensure that factory and site acceptance plans are executed prior to bringing systems into facilities
• Able to visit other manufacturing sites and define 3-5 year digitalization plans based on the current state and the required capital projects and infrastructure required.
• Ensure that IT/OT convergence is properly implemented, including managing interfaces between control systems and enterprise systems such as MES (Manufacturing Execution Systems) and ERP (Enterprise Resource Planning) systems.
• Work with process engineers and operators to develop innovative solutions for improving process efficiency, quality, and safety.
• Work with IT functions to define and mature our cybersecurity and support strategies.
• Monitor and analyze equipment data to identify trends and develop strategies for improving equipment reliability and availability.
• Collaborate with equipment suppliers to develop specifications and standards for equipment procurement and installation.
• Experience with Statistical Process Control (SPC) and other data-driven methodologies for process optimization.
• Experience with historian software and visualization tools for data.
• Knowledge of advanced controls technologies such as Model Predictive Control (MPC), Artificial Intelligence (AI), and Machine Learning (ML), and their applications in manufacturing.
• Expertise in remediating cybersecurity issues with industrial control systems, including vulnerability assessments, risk management, and incident response.
• Mastery of industry standards such as ISA-95, OPC UA, and IEC 62443 for communication and information exchange between control systems and enterprise systems.
• Experience with the design and implementation of advanced visualization and analytics tools for monitoring and controlling processes and equipment.

SKILLS & ABILITIES

• 4-year engineering degree or candidate has 10 years of relevant experience in Automation Controls engineering. 
• The preferred candidate will have at least 10 plus years of maintenance engineering experience.

Experience:

• At least 10 years of experience in the field of controls engineering
• Experience in project management and budget management, including creating and managing project timelines and budgets.
• Knowledge of safety standards and regulations, such as OSHA and NFPA on manufacturing equipment and infrastructure.
• Familiarity with industrial communication protocols such as Modbus, Ethernet/IP, OPC UA, TCP/IP, SSH Telnet and Profibus.
• Experience in project management and budget management, including creating and managing project timelines and budgets.
• In-depth knowledge of maintenance processes and tools, such as predictive maintenance, condition monitoring, and reliability-centered maintenance.
• Strong understanding of process engineering principles, including process optimization, efficiency, and quality improvement.
• Experience with innovation processes, such as design thinking, ideation, and prototyping.
• IT Background in servers, networking, programming, workflows, cybersecurity, and user experience and access.
• Valid driving license and ability to travel across sites (15%-25%)
• Demonstrable ability to support incongruent pieces of manufacturing equipment utilizing hardware from a myriad of manufacturers and programming languages.
• Well-developed presentation skills
• PLC & HMI programming to support all facets of the automated equipment life cycle
• Ability to quickly understand manufacturing processes and adjust and repair to improve and support operations.
• Mastery of Allen Bradley/Rockwell Automation software suite and other software experience (RSLogix500, RSLogix5000, FactoryTalk ME, FactoryTalk SE, RSLinx, FTLinx, FTHistorian, FT Administration Console, FT Directory, ThinManager, Connected Components Workbench, BootP, Trio Motion, Red Lion, Ignition, Siemens, TIA Portal, B&R Automation)
• Significant experience in networking, server maintenance, management, and patching across different sites and software and hardware stacks. Along with evaluating business risk from said activities.
• Patch management on virtualized industrial Automation control systems
• Experience managing contractors.
• Experience in project & resource management
• Ability to diagnose and correct issues on virtual machines and virtual architectures.
• Understand licensing, hardware and software requirements, data transfer, and management of highly complex centralized manufacturing systems hosting hundreds of pieces of production equipment and hardware. This includes an understanding of both the IT portions of systems and the OT portions of systems and how they interact.
• Ability to influence, coach, and lead a team of technical experts.
• Strong proficiency in the Microsoft Office suite including Word, Excel, PowerPoint
• 2d and 3d software modeling and design (AutoCAD, Solidworks, BIM)
• New controls and electrical system design.

Computer Skills:

• Be able to learn and use CMMS software pertaining to work orders
• Experience using basic office computer software, e.g., word processing, power point, excel and project management software (i.e., SmartSheet)
• Can read/understand/troubleshoot PLC software code and program software code for PLCs)

Other Requirements:

• Carries out responsibilities in accordance with the organization's policies.
• Assists with interviewing, hiring, and training maintenance employees; planning, assigning, decision making, and directing work; appraising performance; rewarding and disciplining employees; and addressing complaints and resolving problems.

WORK ENVIRONMENT

• Fast paced, 24/7 heavy manufacturing environment, minimal climate control, loud noises, strong smells

Our compensation reflects the cost of labor across several geographic markets. The annual salary for this position ranges from $108,000.00 in our lowest market up to $132,000.00 in our highest market, plus bonus, equity, and benefits as applicable. The pay for roles at AZEK varies depending on a wide range of factors including but not limited to the specific work location, role, skill set, and level of experience.

AZEK provides a comprehensive benefits package that includes medical, dental, vision, basic life insurance, short- and long-term disability, a 401(k) plan, an employee stock purchase program, and a variety of additional voluntary benefit options. For more details, please visit Benefits @ AZEK or Benefits @ AZEK (Spanish Version). 

Are you concerned that you don’t meet every requirement listed above? Don't let that stop you from applying! Studies reveal that some applicants refrain from applying for jobs unless they fulfill every single requirement. We don't believe in the notion of a "perfect" candidate. If you are confident in your ability to excel in the role, adapt swiftly, and are committed to contributing to our mission of building a more sustainable future, we warmly welcome your application.

Join us in shaping the future of our business!

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