Controls Engineer III - Fanuc Robots & Allen Bradley PLC

The Controls Engineer III Fanuc Robots & Allen Bradley PLC is responsible for the Technical Support functions for power and distribution systems planning and management electrical control systems process planning and process improvements. Involves the different phases of Rheem Manufacturing engineering projects from concept through ongoing production. The incumbent participates in such specific activities as the design and evaluation of processes logic development for programmable logic controllers design and implementation of electrical controls or distribution systems coordination of the plants electrical distribution system and preparation of specifications for bids and proposals. The individual must assist in maintaining technological control over all processes.

This position supports and manages the electrical power and control systems for the entire plant operations and facilities. Electrical technical guidance is provided to others as required in the liaison role between production and all other functional areas of the company. This position also performs engineering and technical assistance in providing economical manufacturing methods to accomplish optimum utilization of machines processes facilities quality and timely production.

This position will serve our Water Heater Division located in Montgomery AL.

• Upload and maintain a current backup of all programs or parameters including documentation for electrical control systems such as Allen Bradley PLCs drives and operator interface terminals. Maintain electrical schematics for all equipment control systems in a central location as well as at the respective equipment.
• Assist plant maintenance in troubleshooting and repair of electrical systems.
• Develop hardware requirements for electrical control systems for process equipment based on required process input and outputs. Develop control programs for programmable logic controllers and operator interface terminals to reflect the process. Maintain and troubleshoot all Allen Bradley PLC equipment hardware and software for the plants processes.
• Calculate and design power requirements for new power feed installations to new process equipment or facilities. Incumbent must determine size and appropriate ratings of transformers wire conduit circuit protection and grounding systems which complies with national electrical codes.
• Investigate and determine the adaptability of new electrical technologies to Rheem facilities and equipment. Prepares specifications and appropriations initiates purchase of capital equipment and oversees their installation and implementation.
• Manages the existing and new installations of the plants power distribution systems. Maintain and update any changes to current singleline electrical diagrams panel drawings panel or distribution centers labeling and systems loads. Makes recommendations to management for changes or adjustments to the power systems.
• Monitors and implements corrective actions to maintain the plants power factor close to unity to prevent penalties from the local power utilities.
• Must provide a proactive communication link of any power demand fluctuations or modifications to plant power facilities to the local power utilities representatives.
• Monitor power systems for any unusual demands or improper operation and report any such activities to management and local utilities for corrective actions.
• Manages the existing and new installations as well as testing to the plants fire protection system. Maintain and update any changes to current system diagrams drawings and documentation. Makes recommendations to management for changes or adjustments to the fire protection systems.
• Plan design and assist in construction and implementation of new control systems to replace antiquated or inefficient control systems on current equipment or processes.
• Develop and assist in the implementation of an electrical preventative maintenance program. Identify critical equipment and its electrical components and initiate predictive programs to replace worn equipment prior to failure to reduce downtime to the operations.
• Participate in cost and productivity improvement projects to reduce utility costs high maintenance costs or excessive downtime with electrical power or control systems.
• Determine the most efficient workstation layout machines tools and operations required to develop optimum line balance for sequential and develops the use of substitute equipment tools and operations to overcome production schedules or technical problems.
• Plan and design new processes and equipment such as electrical control systems jigs fixtures gauges and tools. Develop improvements of special hydraulic pneumatic and electromechanical equipment. After design monitors and controls fabrication progress establishes estimates of time material and labor costs on projects submitted. Project management methods and reports are used to monitor the projects.
• Participate in productivity and quality improvements by investigating analyzing and estimating cost reduction in proposed major changes involving department layouts methods and operation sequence machine utilization tools jigs fixtures and the introduction of automation.
• Investigate the availability of special machines restrictions of workplace layout and available facilities prior to estimation of material labor and machine costs. Obtains necessary data from various sources such as research and development engineering quality control and material costs required to support specific items of equipment or production schedules. Reviews and directs the integration of this information as facets of cost into bid proposals.
• Investigate new process technologies. Determines adaptability to Rheem facilities and product specifications and appropriations initiates purchases of capital equipment and oversees their installation and implementation.
• Develop capability requirements and acceptance criteria for new and existing manufacturing processes.
• Recommend and develop flow layouts.
• Analyze all manufacturing and procedural proposals to determine the most feasible methods the probable capital or expense expenditure requirements and the estimated total cost. Prepare and present both oral and written reports to management along with detailed justification of recommendations.
• Assist in evaluating the condition and providing recommendations as to the effective maintenance of process equipment and electrical systems.
• Investigate and provide solutions for process issues to reduce defects scrap or rework to improve the quality of the product and productivity of the plant.
• Determine ways to reduce workinprocess finished goods inventories raw materials or nonvalueadded activities to aid in controlling operating cost of the facility.
• Interpret instructions and company policy to employees such as ISO 9000 documentation. Maintain standards of performance and training of new personnel discipline good employee management relations improvement of costs and quantity and quality of work of employees.
• Plan devise and document engineering information such as operation sequences materials machines equipment tooling and processes required to manufacture fabricate assemble or process electrical mechanical sheet metal or nonferrous components assemblies and systems of minimum material labor and machine costs.

• Bachelors degree in electrical engineering with five (5) years experience or 8 years of equivalent work experience.
• Able to interact and communicate effectively at the engineering technical level with people in and outside the company.
• Must possess effective verbal and written skills to communicate technical analysis of problems and reports.
• AutoCAD or similar computeraided drafting.
• Significant training and experience in developing logic for programmable logic controllers and operator interface terminals and schematics for industrial electrical control systems.
• Experienced in troubleshooting industrial electrical control systems programmable logic and drive systems.
• Experience in Power systems planning power distribution systems singlephase and threephase substation transformers power feed sizing motor control centers etc.
• Experienced in various types of motors: AC DC singlephase motors threephase motors synchronous motors etc.
• Knowledge of PC software applications such as spreadsheets word processors presentations and project management a must.
• Knowledgeable in National Electrical Codes and industrial wiring practices.

HOW TO STAND OUT

• Fanuc robotics and Allen Bradley Motion.
• Previous experience with equipment upgrades to include Allen Bradley Logix 500 to 5000.
• AutoCAD Electrical experience.
• Knowledgeable of pneumatic hydraulic and mechanical systems.
• Experienced in control systems integration.

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