Electrical & Instrumentation Design Engineer

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JOB PURPOSE

Manage engineering activities within the digitalisation and Instrumentation discipline of a Global Business Unit, establishing and maintaining technical standards. Responsible for Instrumentation & Controls and SCADA projects, including design and implementation.

Responsible for implementing and rolling out process improvement strategies by developing plans to enhance machinery efficiency and effectiveness.

Execute support requests, upgrades, unification, and continuous improvements of all automation and control systems related to various equipment and machinery in use across all Operating Plants.

Financial Dimensions:

• Efficient management of Industrial Control Systems
• Reduction of equipment breakdown costs
•  Improvement of operating efficiency
•  Reduction of labour requirements and costs through automation
•  Reduction of production costs by expanding the machine range of products and output
• Management of Upgrade Projects

KEY ACCOUNTABILITIES

 Digitalisation

• Lead the strategy of digitalisation to transform the manufacturing plants to Industry 4.0 using Industrial IoT,
• Support the solution vendor in the integration and configuration of the MES system,
• Identify and resolve issues to minimize MES disruptions; request support from the vendor when needed,
• Work towards maximizing the return on investment in MES systems,
• Provide training to the workforce to ensure effective utilization of the MES system; provide support, including maintenance and upgrades.

 Electrical & Instrumentation Design Engineering

•  Define appropriate instrumentation for production and process control (temperature, pressure, level, weight, flow, motion measurement),
• Develop evaluations, drawings, analyses, and procedures to document new designs,
• Implement PLC-based process control and instrumentation package,
• Lead the design and development of new Control Systems,
• Upgrade, test and maintain existing systems,
• Define the utilities capacity requirements for new equipment.

Machinery Upgrade & Project Management

•  Manage the group machinery upgrade projects,
• Implement a corporate wide ICS and SCADA vision with guidelines and directives.
• Coordinate and Direct activities of vendors and internal personnel in installation of new equipment,
• Provide a comprehensive system overview and detailed planning for upgrading control systems, including full SCADA diagnostics.
• Identify upgrade project deliverables, define requirements, create design documents, and contribute to design reports,
• Provide technical and plant support roles for the internal/external teams to supplement capital project work,
• Prepare, review, and finalize cost estimates for new upgrade,
• Define scope of supply, acquire offers and negotiate the final cost.

Software Development & Networking

• Develop and maintain Industrial Communication Networks and protocols (such as Modbus, Serial RS485, Profinet).
• Create software application systems, including Product Recipes Database and user interfaces.
• Develop industrial automation programming solutions for Human Machine Interface (HMI).
• Plan, design, and implement Data Acquisition Systems with real-time communication between various devices.
• Oversee the Cloud system relevant to group machine operation.
• Ensure acquisition and secure backup maintenance of Software Source Code for all machines.
• Manage and support Software Licenses, ensuring compliance, agreements, and yearly renewal processes.

Automation & Control Support

• Ensure the uninterrupted operation of the group's industrial control systems (ICS) and Supervisory Control and Data Acquisition (SCADA) systems.
• Develop programs and code for CNC, PLC, HMI, and SCADA software.
• Configure VFDs, adjust instrumentation settings, and perform calibrations as needed.
• Assist operating plants in troubleshooting breakdowns of Electrical, Automation, and Control systems.
• Establish secure networking protocols for remote troubleshooting and software upgrades, providing timely support from a distance.
• Provide essential technical expertise to electrical maintenance teams, aiding in efficient troubleshooting processes.
• Analyse and promptly address automation troubleshooting inquiries, including traveling if necessary to provide urgent support to operating plants.
• Design, modify, test, and launch PLC and HMI automation projects.
• Troubleshoot and repair group-wide PLC & CNC control systems, MCC equipment, VFDs, Induction Heaters, Flow Dosing systems, and High-Pressure Testing Equipment.

Equipment Design

•  Lead the Implementation of innovative technologies in the design of new machines & production lines related to electrical, automation, instrumentation, and control.

 Technology Sourcing

• Identify and assess new technologies and suppliers globally,
• Evaluate proposals from vendors and make recommendations on equipment purchases, software upgrades and system components acquisitions,
• Lead the formulation of the most competitive and best value agreements for rapid and sustainable savings,
• Follow up with procurement teams to ensure timely issuance of purchase orders for new equipment and machine components.

Machinery Development & Improvement

• Ensure the provision of an optimal automation process that meets the design requirements, efficiency standards, and safety protocols of the company's systems.
• Rollout the successfully tested equipment and machine components in the group.

Commissioning Project Management

• Lead and actively support continuous improvement initiatives spanning a wide spectrum of upgrades.
• Implement and oversee the execution of rolled-out upgrades and automation projects across the organization.
• Provide accurate cost estimates for process automation and improvement projects to ensure budgetary adherence.
• Develop comprehensive operating and troubleshooting manuals for newly implemented projects.
• Strategically plan upgrade project preparation and meticulously oversee implementation phases.
• Provide on-site supervision during plant and equipment installation and erection phases.
• Conduct the start-up of electrical systems, equipment, and instrumentation, including Factory Acceptance Testing (FAT) and Site Acceptance Testing (SAT) for both process and mechanical equipment.
• Lead a dedicated technical team to ensure timely completion of commissioning projects.
• Compile and analyse data to prepare insightful reports for existing and potential engineering studies and projects.
• Develop Bill of Materials (BOM) estimates for machinery development projects to establish preliminary budgets.
• Monitor and facilitate the design development and progress of manufacturing suppliers.
• Verify and commission components manufactured externally to uphold quality standards and specifications.

HSE

• Investigate electrical fire incidents and establish corrective and preventive actions,
• Conduct thorough investigations into electrical fire incidents and devise effective corrective and preventive actions to mitigate future risks.
• Collaborate closely with the Health, Safety, and Environment (HSE) Engineer to identify and prominently display safety requirements for each machine.
• Ensure strict adherence to pertinent safety, quality, and environmental control procedures and instructions throughout operations.