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Controls Engineer III

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Date: Jun 2, 2021

Location: Durham, NC, US, 27712

Company: Corning

Requisition Number: 43438

 

Corning is one of the world's leading innovators in materials science, with a 166-year track record of life-changing inventions. Corning applies its unparalleled expertise in glass science, ceramics science, and optical physics, along with its deep manufacturing and engineering capabilities, to develop category-defining products that transform industries and enhance people's lives. Corning Valor™ Glass is an example of a life-changing innovation purpose-built to store and protect injectable medicines. Corning is also a global leader in pharmaceutical tubing, manufacturing a variety of clear and amber glass tubing that is converted by our customers into vials, cartridges, ampules and syringes.

Purpose of Position: Completes engineering and automation projects in a manufacturing environment. Specifies, procures, and completes projects to automate production processes, improves machine controls, and install machine data reporting. Supports automation and controls in a manufacturing environment. Designs new electrical controls systems and improves existing electrical controls systems. Manage projects from design to implementation, including defining project scope, determining required resources, establishing equipment specifications, providing system startup services, developing processes and executing validation protocols. Ensures compliance/improvement of quality systems in manufacturing (i.e. ISO, QSR, GMP). Participate in new product development and process improvement projects as a core team member or core team leader.

Key Responsibilities:  

  • Lead automation upgrades on existing equipment to improve process reliability and costs.  
  • Work with representatives from operations, maintenance/facilities and quality engineering to justify, design, develop and implement improvements to equipment and equipment controls.  
  • Introduce new sensors and controls and modify PLC programs or add PLCs to improve functionality of existing equipment.  
  • Introduce new mechanical systems to improve functionality of existing equipment.  
  • Work with outside automation vendors on equipment improvement projects.  
  • Supervise the installation, startup, testing and debug of new or modified manufacturing equipment and controls.
  • Manage capital equipment projects from concept through implementation ensuring that all performance specifications and project objectives are met on schedule and on budget.  
  • Develop technical specifications for automated manufacturing equipment (mechanical performance requirements, and automation and controls functionality and design).  
  • Prepare capital appropriations requests including analysis of existing operations, estimation of project costs, and justification of proposed actions.  
  • Develop bid documents for the procurement of process control systems (software and hardware).  
  • Manage vendors to ensure systems meet specifications.  
  • Collaborate with quality engineering to establish and execute equipment acceptance and validation protocols.  
  • Design and deploy data collection systems on production process and utility equipment and link them to the Manufacturing Execution System (MES) to report process and utility output, utilization, yield, and power consumption, and gather critical to quality process data to allow engineering and SPC analysis of operations.  
  • In concert with manufacturing engineers and electrical controls engineer, maintain a centralized library of updated versions of controls software for all process equipment.  
  • Document and archive all engineering changes such as PLC programs and electrical schematics. 
  • Recommend and implement changes to control hardware and software versions to keep systems current and supportable.  
  • Perform hands-on troubleshooting and process improvements in manufacturing operations.
  • Use root cause analysis to eliminate process problems.  
  • Provide technical support and troubleshooting for automated mechanical systems, electrical controls, and robots.  
  • Train engineers and technical support personnel as needed on controls and machine operation. Support operations with controls issues.  
  • Ensure compliance/improvement of quality systems in manufacturing (i.e. ISO, QSR, GMP).  
  • Revise all necessary documentation to maintain the quality system.  
  • Directs the activities of internal and external resources during the completion of project work, process troubleshooting and machine improvement activities.  
  • Oversees the work of internal and external electrical and controls technicians to ensure that their work adheres to company standards, and local, state, and federal codes.  
  • Work as a member of the Electrical Support Team that responds to manufacturing process upsets or plant system downtime events during off hours as needed.

Minimum Qualifications:  

  • BS in Electrical Engineering or related engineering field (automation, controls).  
  • Minimum of 8 years of experience designing and implementing automation solutions in a manufacturing environment  
  • Experience programming PLC’s and implementing HMI’s.

Travel Requirements:  

  • Short term (first 1-6 months): up to 50%  
  • Long term (>6months) 
  • We anticipate less than 5% travel is required for this role.

Hours of work/work schedule:  

  • Monday – Friday, 8:00 – 5:00 pm  
  • Expect 45-50 hours per week on average.  
  • Weekend work required during start-ups and major projects or process activity.

Skills/Experience:  

  • Demonstrated experience troubleshooting, process controls, electrical equipment, PLC programs, HMI applications, sensors, valves, motors, drives, VFD motion control.  
  • Must be proficient with AutoCAD for electrical design work.  
  • Experience with PLC controlled high speed automated assemble equipment.  
  • Proficiency with Microsoft Project desired.  
  • Experience in Project Management involving high speed automation equipment introductions preferred.  
  • Experience with PLC manufacturers: Allen Bradley, Siemens, GE, Omron preferred.  
  • Experience with robots used in pick and place applications, including programming robot moves, instructing positions and troubleshooting problems preferred.  
  • Experience programming and troubleshooting motion control systems using equipment from manufacturers like Allen-Bradley, Control Techniques, and Compumotor preferred.  
  • Experience with injection molding machines and extruders preferred.

 

This position does not support immigration sponsorship.

We prohibit discrimination on the basis of  race, color, gender, age, religion, national origin, sexual orientation, gender identity or expression, disability, or veteran status or any other legally protected status.

We will ensure that individuals with disabilities are provided reasonable accommodation to participate in the job application or interview process, to perform essential job functions, and to receive other benefits and privileges of employment. Please contact us to request accommodation.


Nearest Major Market: Durham
Nearest Secondary Market: Raleigh