PLC Programmer

Position Summary

Under the direction of the Technical Manager, the incumbent’s role is to provide process control and instrumentation support for HSH Bauxite, to achieve and sustain reliable equipment operation, to improve capacity and efficiency though Process Control Optimization.  

The incumbent will further be responsible for maintaining the Process Control infrastructure; all field and automation systems hardware, inclusive of Honeywell DCS and Modicon Quantum PLCs. In addition, she/he will have sufficient knowledge to be able to troubleshoot these systems and serve as the site ICS administrator. Incumbent will need to be capable or willing to train in other system program languages such as Allen Bradley or others as needed in the plant. 

Coordinating with the maintenance planner and operations team the incumbent is responsible for the planning and execution of all Process Control development work & troubleshooting instrumentation functionality. She/He is responsible for auditing, tracking, and correcting unsafe conditions when found, and ensuring that employees comply with all environmental, health and safety rules, regulations, and procedures. The incumbent is responsible for applying the Huber Principles and promoting those principles with employees.  
 

Principal Duties & Responsibilities

• Work with plant personnel to troubleshoot process control issues.
• Work with plant personnel to optimize existing process control logic.
• Support the Project Engineers when justifying, planning, or directing contractor related activities. 
• Evaluate new process control technologies.
• Supervise controls tasks conducted by employees, including training and corrective action.

Major Challenges: 

• Optimizing existing processes, while minimizing the impact to production.  
• Communicating project needs and requirements to management.
• Work execution that ensures a minimum amount of downtime.

Planning and Scheduling Responsibilities:

• Assist with planning & scheduling of all Process Control or Instrumentation type activities.
• Participate in the maintenance scheduling meeting. 
• Track all parts inventory and maintain min/max levels.

Process Control Systems Management and Administration

• Process development activities to include creation/modification of process, flow diagrams, piping and instrument diagrams, equipment specs, control logic, etc.
• Program PLC and DCS changes and new installations.
• Modify plant process control systems, install and commission field instrumentation to acquire process data and trending for analysis/process troubleshooting.
• Support manufacturing and operations in issues of process control and technical problem solving.
• Maintain company-required performance and maintenance records for identified equipment.
• Develop and maintain calibration and records program for process instrumentation, scales, and product test equipment.
• Assist, facilitate, and develop training for maintenance and other technical level employees.
• Troubleshoot and direct repairs for electronic equipment, including programmable and numeral controls, power supplies, drives, gauges, and test equipment.
• Assist maintenance personnel with technical troubleshooting.
• Support preventive maintenance functions as directed.
• Maintain and support the process data historian.
• Actively participate and support Bauxite Operational Excellence opportunities.
• Access software and set passwords.
• Make logic changes for improved process control as determined by management or as approved through the management of change process.
• Install and configure new instrument/electrical and controls hardware.
• Program and tune control loops in the control builder application software.
• Set up quick builder points for information exchange with the modicon system.
• Other duties as assigned.

Project Management Responsibilities:

• Work with Engineers, Contractors, Vendors and Consultants to plan, install, upgrade, remove, or recondition equipment or systems.
• Keep electrical/ instrumentation drawings up to date.
• Assist with selection of Electrical Engineers, Contractors, Vendors and Consultants.

Other General Responsibilities:

• Participate and execute changes per the management of change process as it relates to instrumentation and controls.
• Provide necessary tools, materials, and spare parts that are required to complete daily assigned tasks. 
• Attend daily production meetings and help to coordinate instrumentation tasks to meet daily production needs. Participate in maintenance planning meeting to establish equipment downtime requirements, PMs and communicate status of active maintenance jobs.
• Ensure that labor cost is distributed to the proper charge numbers and employee exceptions are cleared in the payroll system.
   

Specialized/Technical Knowledge or Required Skills

• A bachelor’s degree in a related field preferred.
• Minimum five years of experience in instrumentation, electronic, electrical and mechanical systems specification and installation; and the maintenance of these systems. 
• High School Diploma/GED is required. 
• Thorough knowledge of process control and instrumentation theories and principles, writing specifications, local and national codes and properties of various materials, and principles of operation of electronic equipment.
• To perform this job successfully, an individual should have knowledge of and ability to use Internet software, manufacturing software, spreadsheet software, word processing software and knowledge of Oracle (or similar software.)