What are the responsibilities and job description for the Automation Engineer position at AprilAire?
Overview
AprilAire is currently seeking an Automation Controls Engineer to join our growing manufacturing engineering team! We are seeking a highly skilled and detail-oriented engineer to drive standards for PLC, HMI, and industrial controls across our two manufacturing facilities. The ideal candidate will develop, implement, and maintain programming and connectivity standards that enhance manufacturing performance, continuous improvement (CI) initiatives, and data collection capabilities.
This position will require onsite commitments to both our Madison and Poynette facility.
Responsibilities
Standards Development:
Develop, implement, and maintain comprehensive standards across all levels of automation and control, including PLCs, HMIs, servo controllers, and consumable electrical components (e.g., fuses, relays, and connectors).
Ensure consistency in control hardware, software, and consumable components used across both sites to optimize system reliability and reduce downtime.
Collaborate with cross-functional teams to uphold high standards in all control-related elements, from advanced automation systems to essential consumable electrical components.
Development Of Equipment Logic/Motion Control
Design and develop equipment logic and motion control programs from scratch to automate new machinery and systems.
Define functional requirements, sequence of operations, and safety protocols for equipment control systems.
Implement precise motion profiles for servos and other actuators, optimizing performance and ensuring smooth and efficient equipment operation.
Perform system simulations and virtual commissioning using tools like Emulate3D to validate and refine logic before deployment.
Collaborate with mechanical and process engineering teams to ensure seamless integration of motion controls with overall equipment design.
Programming And Troubleshooting
Create, maintain, and improve PLC programs to drive automation, enhance process control, and integrate connectivity and data collection capabilities.
Troubleshoot complex PLC programming and electrical control issues with a systematic approach to root cause analysis.
Work with Rockwell and Mitsubishi PLCs, leveraging their respective motion control functionalities for advanced automated solutions.
Project Management
Collaborate with cross-functional teams to identify and implement CI opportunities in automation, connectivity, and data acquisition.
Optimize production processes by integrating automation solutions to minimize downtime, maximize throughput, and improve quality.
Technical Support
Provide expertise in electrical component troubleshooting, resolving issues quickly to maintain production continuity.
Act as a technical resource for both maintenance and production teams, training and mentoring team members on controls and automation best practices.
Documentation & Compliance
Ensure all programming, wiring, and installation procedures comply with safety, quality, and regulatory standards.
Maintain clear and thorough documentation for all controls systems and standards, including code comments, wiring diagrams, and change logs.
Data Collection & Connectivity
Implement data collection strategies for real-time performance monitoring, analytics, and reporting.
Establish connectivity for integration with MES, ERP, and other factory information systems to support data-driven decision-making.
Qualifications
Bachelor’s Degree in Electrical Engineering, Automation, Controls Engineering, or a related field.
5 years of experience in industrial automation, PLC programming, and controls within a manufacturing environment.
Proven experience with both Rockwell and Mitsubishi PLC platforms, with high-level proficiency in motion controls.
Hands-on experience troubleshooting complex electrical systems, control components, and software.
Proficiency in AutoCAD Electrical for control system schematics and SolidWorks for mechanical design of control enclosures and components.
Experience with Emulate3D for virtual commissioning, simulation, and testing of control systems and automation setups.
Advanced skills in Rockwell programming software (e.g., RSLogix 5000, Studio 5000, FactoryTalk) and Mitsubishi programming software (e.g., GX Works, GT Works for HMI programming).
Knowledge of data collection and connectivity principles for MES/ERP
Advanced understanding of electrical schematics, wiring diagrams, and industrial components.
Project management experience.
Familiarity with Lean Manufacturing and Six Sigma methodologies desired.
Experience with IIoT for smart factory integration a plus.
Experience with 10 in 6 software a plus.
AprilAire is currently seeking an Automation Controls Engineer to join our growing manufacturing engineering team! We are seeking a highly skilled and detail-oriented engineer to drive standards for PLC, HMI, and industrial controls across our two manufacturing facilities. The ideal candidate will develop, implement, and maintain programming and connectivity standards that enhance manufacturing performance, continuous improvement (CI) initiatives, and data collection capabilities.
This position will require onsite commitments to both our Madison and Poynette facility.
Responsibilities
Standards Development:
Develop, implement, and maintain comprehensive standards across all levels of automation and control, including PLCs, HMIs, servo controllers, and consumable electrical components (e.g., fuses, relays, and connectors).
Ensure consistency in control hardware, software, and consumable components used across both sites to optimize system reliability and reduce downtime.
Collaborate with cross-functional teams to uphold high standards in all control-related elements, from advanced automation systems to essential consumable electrical components.
Development Of Equipment Logic/Motion Control
Design and develop equipment logic and motion control programs from scratch to automate new machinery and systems.
Define functional requirements, sequence of operations, and safety protocols for equipment control systems.
Implement precise motion profiles for servos and other actuators, optimizing performance and ensuring smooth and efficient equipment operation.
Perform system simulations and virtual commissioning using tools like Emulate3D to validate and refine logic before deployment.
Collaborate with mechanical and process engineering teams to ensure seamless integration of motion controls with overall equipment design.
Programming And Troubleshooting
Create, maintain, and improve PLC programs to drive automation, enhance process control, and integrate connectivity and data collection capabilities.
Troubleshoot complex PLC programming and electrical control issues with a systematic approach to root cause analysis.
Work with Rockwell and Mitsubishi PLCs, leveraging their respective motion control functionalities for advanced automated solutions.
Project Management
- Plan, coordinate, and manage projects related to controls, automation, and integration, ensuring alignment with plant goals, timelines, and budget.
Collaborate with cross-functional teams to identify and implement CI opportunities in automation, connectivity, and data acquisition.
Optimize production processes by integrating automation solutions to minimize downtime, maximize throughput, and improve quality.
Technical Support
Provide expertise in electrical component troubleshooting, resolving issues quickly to maintain production continuity.
Act as a technical resource for both maintenance and production teams, training and mentoring team members on controls and automation best practices.
Documentation & Compliance
Ensure all programming, wiring, and installation procedures comply with safety, quality, and regulatory standards.
Maintain clear and thorough documentation for all controls systems and standards, including code comments, wiring diagrams, and change logs.
Data Collection & Connectivity
Implement data collection strategies for real-time performance monitoring, analytics, and reporting.
Establish connectivity for integration with MES, ERP, and other factory information systems to support data-driven decision-making.
Qualifications
Bachelor’s Degree in Electrical Engineering, Automation, Controls Engineering, or a related field.
5 years of experience in industrial automation, PLC programming, and controls within a manufacturing environment.
Proven experience with both Rockwell and Mitsubishi PLC platforms, with high-level proficiency in motion controls.
Hands-on experience troubleshooting complex electrical systems, control components, and software.
Proficiency in AutoCAD Electrical for control system schematics and SolidWorks for mechanical design of control enclosures and components.
Experience with Emulate3D for virtual commissioning, simulation, and testing of control systems and automation setups.
Advanced skills in Rockwell programming software (e.g., RSLogix 5000, Studio 5000, FactoryTalk) and Mitsubishi programming software (e.g., GX Works, GT Works for HMI programming).
Knowledge of data collection and connectivity principles for MES/ERP
Advanced understanding of electrical schematics, wiring diagrams, and industrial components.
Project management experience.
Familiarity with Lean Manufacturing and Six Sigma methodologies desired.
Experience with IIoT for smart factory integration a plus.
Experience with 10 in 6 software a plus.
