Automation Engineer

At Sonoco Chesterfield we manufacture composite cans used as packaging mainly for food and powdered beverages. We are aiming to be one of the first fully paperboard cylindrical packing suppliers, where our packaging is durable and 100% recyclable.

Purpose of Job: Within the operations department and reporting directly to the Engineering Manager, your role is to improve the efficiency and reliability of our plant manufacturing processes by application automation.

Your day to day job will consist of:

• Supporting the production and engineering team through line breakdowns, supporting fault finding of the root cause and designing the issue out in the shortest period possible.
• Running Automation projects to plan for continued upgrade of equipment and control systems, ensuring none of our equipment becomes obsolete and out of date.
• Additional support required for: 5S, SMED, Centre lining, Process Control Automation, product defect identification systems, component lifespan identification.
• Machines installation & qualifications on site: Factory Acceptance Test, Commissioning, Team Training.
• New products introduction: trials of new materials and new products launch support at manufacturing level.

Role within the company and stakeholder interactions: The candidate will report to the site Engineering Manager and will have to interact with multiple stakeholders on a day-to-day basis: Manufacturing, Engineering, Warehouse, Supply Chain, sister plants (based in Europe), Suppliers. The Automation Systems Engineer will be expected to be a subject matter expert and be able to guide/mentor engineers within the business.

Key Activities:

• Provide technical support to all areas daily across electrical, mechanical and automation disciplines.
• Configuration and programming of controllers and visualizations systems using Siemens (Simatic Manager and TIA Portal and WinCC flexible software).
• Project planning and programming of drive technology and servo drives – with emphasis on SEW Drive as well as Allen Bradley systems.
• Development, conception, design and creation of hardware / circuit diagrams.
• Automation troubleshooting following a recognisable troubleshooting process.
• Experience with bus systems and bus technology such as “Profinet” and “Profibus” with knowledge of systems such as ASI bus and CAN bus.
• Project Management and Project Coordination of site automation projects.
• Utilise AutoCad/Cad systems to maintain documentation updates, producing 2D CAD drawings of control panels, P&IDs and electrical wiring diagrams.
• Provide onsite services to assist in start-up or troubleshooting.
• Support and lead automation activities at both the Chesterfield and Bradford Production Sites.
• Develop HMI’s for operator use.
• Coordinating with cross-functional team(s) to resolve automation issues.
• Write programs for new designed automatic and semi-automatic machines and conveyor systems for Siemens and Allen Bradley hardware.
• Debug and test new or modified PLC and robotic programs on the production floor.
• Conduct comprehensive machine and system testing.
• Ensure the department operates with due regard to current legislation, company and statutory requirements.
• Ensure the safe and efficient operation of equipment throughout the site.
• Installation of production and plant equipment, commissioning, breakdown analysis and repair.
• Identify areas in which engineering improvements can be made to increase safety, quality, efficiency, or reduce waste.
• Assist with the training of company apprentices and shift Engineers.
• Assist with developing operational manuals for newly designed machines and conveyor systems.
• Assist in risk assessment of newly designed machines with emphasis on machine safety.
• Help refine and develop programming standards and methods.
• Coordinate with other engineers and programmers on large systems and machines.
• Maintain and enhance the software and robotics solutions for the two sites.
• Maintain and document the appropriate software changes and updates to support equipment modifications and continuing operation.
• Work with Manufacturing/Operations to identify and troubleshoot machine control failures.
• Specify instrumentation and control hardware for equipment upgrades and future equipment lines.
• Will keep in line with new technology and advise the site accordingly.
• Running testing and diagnostics on IT systems to identify potential problems.
• Identifying and resolving malfunctions within the system.
• Developing and installing new hardware or software to update and improve the functionality of systems.
• Liaising with outside suppliers or developers to source the most effective hardware or software for the company’s needs.
• Creating schematics plans of the system.
• Building robust backups that can be accessed in the event of system failure.
• Training shift Engineers and Process Improvement Engineers to work within the systems and to resolve issues on their own.
• Liaising with operational staff to ensure that systems can complete designed tasks.
• Lead improvement activities/projects across site, covering all equipment and facilities.

Key Measurables:

• % Unplanned Downtime on focus machinery
• % Implementation of project work
• % People trained to correct operating level on focus machinery
• % People trained on problem solving
• $ saved by continuous improvement projects implemented

CANDIDATE’S EXPERIENCE

Qualifications and Experience

• Required: HNC/Degree qualified Electrical Engineering
• Proven Knowledge and experience in Siemens S5, S7, Allen Bradley (this includes all aspects of drives, inverters and programming)
• Proven capability in Problem Solving (8D, Green Belt Lean 6 Sigma, UPS, A3, ...)
• Experience in a FMCG environment

• Desirable: Graduate Masters / Bachelor in a Technical / Manufacturing / Sciences subject
• 2 years or more of experience in a process control / engineering role
• Electrically Biased multiskilled Engineering background
• Lean Six Sigma Green Belt qualified or equivalent

Skills and Knowledge

• Ability to analyse complex sets of data quickly.
• Prioritise activities based on daily workload and medium projects.
• Ability to train and coach people.
• Excellent communication: written, spoken, visual.
• Excellent computer skills: mainly Microsoft Excel, PowerPoint, and email.

Personal Attributes

• Must be curious.
• Must be willing to learn and develop personal knowledge.
• Bias for action / Enthusiastic with drive for continuous improvement.
• Must be an excellent team player with good interpersonal skills able to communicate at all levels.
• Logical with a key eye for details.
• Excellent customer focus required.
• Must be willing to travel, both UK and Europe.

Working Environment

The position is based in Chesterfield plant but can require visits to our manufacturing plants in UK & Europe as well as visits to our Suppliers or Customers in the UK.