Automation Lead Engineer

John Cockerill; Navi Mumbai; On-site; INR 1,200,000 - 2,100,000; Full time

Job summary

John Cockerill in Navi Mumbai seeks an experienced Senior/Lead Engineer for Cold Rolling Mill Automation, Engineering and Commissioning. The role demands hands-on design, PLC/HMI software development, and expertise in mill technology, process control, and system integration.

You will lead commissioning teams, coordinate with customers and global vendors, and drive successful project execution and site handover.

Qualifications

• Senior engineer with 10–15+ years in industrial automation for cold rolling mills.
• Expertise in PLC programming, control narratives, interlocks and system architecture.
• Experience leading commissioning teams and site handover activities.
• Strong collaboration with electrical, instrumentation and process teams.

Responsibilities

• Develop automation philosophies, specifications, I/O lists and interlock matrices.
• Select PLC hardware, size CPU, configure I/O and network architecture.
• Coordinate with multi-discipline engineering teams and vendors.
• Lead commissioning, FAT/SAT, and site handover with customers.
• Optimize AGC/RGC, tension control and roll mill automation loops.
• Manage PLC logic, HMI, diagnostics, and fault recovery functions.

Skills

PLC programming

HMI development

Siemens S7

TIA Portal

Roll mill automation

Team leadership

Education

B.E./B.Tech. in Electrical/Electronics/Instrumentation

Tools

Siemens S7-300/400/1500

TIA Portal

STEP 7

WinCC

PROFINET/PROFIBUS

EtherNet/IP/OPC UA

Job description

Senior / Lead Engineer Cold Rolling Mill Automation, Engineering & Commissioning

Experience: 10–15+ Years

Qualification: B.E./B.Tech. in Electrical, Electronics, or Instrumentation Engineering

Platforms: Siemens, ABB, Rockwell Automation

1. Job Profile

Looking for an experienced Cold Rolling Mill Automation Engineer with strong hands-on expertise in engineering design, PLC/HMI software development, mill technology, advanced process control, system integration, and site commissioning. The candidate must independently manage engineering activities, lead commissioning teams, coordinate with customers and vendors, and ensure successful project execution and site handover.

2. Key Responsibilities

A. Engineering & System Design

• Develop automation philosophies, functional specifications, system architecture, I/O lists, interlock matrices, and control narratives.
• Handle PLC hardware selection, CPU sizing, distributed I/O configuration, network architecture, and drive-system integration.
• Coordinate with electrical, instrumentation, process, drive, and hardware engineering teams.

B. Mill Technology & Process Control

• Strong knowledge of cold rolling mill technology, tension control, speed synchronization, and drive coordination.
• Hands‑on expertise in Roll Gap Control (RGC), Automatic Gauge Control (AGC), and Skin‑Pass Mill (SPM) automation.
• Develop and optimize feedback, feedforward, mass–flow, rolling‑force, pressure, and elongation control loops.
• Understand hydraulic control, oil‑film/Moog‑related compensation, and roll eccentricity compensation.

C. PLC Software & HMI Engineering

• Expert in Siemens S7-300/S7-400/S7-1500, TIA Portal, STEP 7, and WinCC.
• Proficiency in LAD, SCL, STL/AWL for legacy systems, FBD/CFC, and GRAPH.
• Develop PLC logic, automatic sequences, interlocks, diagnostics, and fault recovery functions.
• Configure HMI faceplates, popups, alarms, trends, data archives, and reports.
• Knowledge of safety PLCs, ABB, and Rockwell Automation platforms is desirable.

D. System Integration & Level 2 Automation

• Integrate gauge measurement systems, Automatic Flatness Control (AFC), Process Data Acquisition (PDA), drives, and third‑party equipment.
• Hands‑on experience with PROFINET, PROFIBUS, EtherNet/IP, OPC UA, Modbus TCP, and applicable industrial protocols.
• Develop and troubleshoot Level 1/Level 2 interfaces, setpoint transfer, process data exchange, and communication handshakes.

E. Commissioning & Site Leadership

• Execute FAT, SAT, cold commissioning, dynamic testing, and production commissioning.
• Commission and optimize AGC, RGC, tension control, SPM, drive coordination, and automatic sequences.
• Independently lead site commissioning teams and resolve complex automation, drive, instrumentation, and process‑control issues.
• Coordinate with customers, vendors, and international engineering teams to maintain project schedules and customer satisfaction.
• Conduct site progress meetings, maintain Minutes of Meeting (MoM), and ensure timely closure of punch points.
• Take ownership of customer acceptance, final sign‑off, documentation, and successful site handover.

3. Essential Requirements

• 10–15+ years of relevant industrial automation and engineering experience, preferably in cold rolling mills.
• Strong expertise in Siemens PLC programming, TIA Portal, STEP 7, WinCC, AGC, RGC, tension control, and SPM automation.
• Proven experience in engineering design, system integration, software development, and independent site commissioning.
• Strong technical leadership, troubleshooting, customer coordination, and project execution capabilities.
• C/C++ knowledge is desirable; ABB and Rockwell Automation experience is an advantage.
• Willingness to travel domestically and internationally for project execution.