Senior Automation Engineer

John Cockerill; Navi Mumbai; On-site; INR 4,000,000 - 7,000,000; Full time

Job summary

John Cockerill is seeking an experienced Senior/Lead Engineer for Steel Processing Line Automation, Engineering and Commissioning in Navi Mumbai. The role demands hands-on engineering design, PLC/HMI development, drive coordination and site commissioning, with preference for extensive experience in continuous strip lines.

You will independently manage engineering deliverables, lead commissioning teams, coordinate with customers and vendors, and ensure successful project execution and formal

Qualifications

• Minimum 10–15 years of industrial automation experience.
• Strong hands-on expertise in Siemens PLC programming and HMI/SCADA.
• Experience with drive coordination, system integration and commissioning.
• Practical knowledge of Level 1/2 integration and third-party communication.
• C/C++ knowledge is desirable; ABB/Rockwell experience is a plus.

Responsibilities

• Engineering & system design including specifications and architecture.
• Lead commissioning teams and coordinate with customers and vendors.
• Develop PLC/HMI software, interlocks, diagnostics and fault recovery.
• Integrate process controls for continuous strip processing lines.
• Manage documentation, FAT/SAT, and site handover.
• Coordinate with multi-disciplinary teams across disciplines.

Skills

Siemens PLC programming

TIA Portal

STEP 7

WinCC

Process automation

Commissioning

Project leadership

C/C++ knowledge

Education

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

Tools

PROFINET

PROFIBUS

EtherNet/IP

OPC UA

Modbus TCP

Job description

Senior / Lead Engineer Steel Processing Line Automation, Engineering & Commissioning

Experience: 10–15+ Years

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

Automation Platforms: Siemens, ABB, Rockwell Automation

Applications: CGL, CAL, CAPL, PPPL, Pickling Lines, Recoiling Lines, and other Continuous Strip Processing Lines

1. Job Profile

We are seeking an experienced Steel Processing Line Automation Engineer with strong hands‑on expertise in engineering design, PLC/HMI software development, process automation, drive coordination, system integration, and site commissioning. The candidate must possess in-depth knowledge of continuous strip processing technology and independently manage engineering deliverables, 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, control narratives, system architecture, I/O lists, interlock matrices, and equipment specifications.
• Handle PLC/CPU selection, distributed I/O configuration, network architecture, drive‑system integration, and hardware engineering coordination.
• Coordinate with electrical, instrumentation, process, mechanical, drive, and third‑party engineering teams.

B. Processing Line Technology & Process Control

• Strong understanding of CGL, CAL, CAPL, PPPL, pickling lines, and other continuous strip processing applications.
• Knowledge of strip threading, welding, entry/exit sections, bridle rolls, tension regulation, speed synchronization, strip accumulation, and recoiling.
• Hands‑on expertise in strip tension control, master‑follower drive coordination, speed and torque control, and coordinated line operation.
• Understand process‑specific technologies, including pickling, annealing, galvanizing, skin‑pass rolling, chemical treatment, and strip surface processing, as applicable to the line.
• Knowledge of furnace temperature control, atmosphere regulation, strip cooling, coating control, and process sequencing, depending on the application.

C. PLC Software & HMI/SCADA Engineering

• Expert‑level hands‑on experience in Siemens S7‑300/S7‑400/S7‑1500 PLCs, TIA Portal, STEP 7, and WinCC.
• Proficiency in LAD, SCL, STL/AWL for legacy systems, FBD/CFC, and GRAPH.
• Develop modular PLC software, automatic sequences, interlocks, permissive, equipment coordination, diagnostics, and fault‑recovery logic.
• Configure HMI faceplates, popups, process graphics, alarms, trends, data archives, and production reports.
• Knowledge of safety PLCs, distributed I/O, and industrial network diagnostics.
• ABB and Rockwell Automation platform experience is highly desirable.

D. Drive Systems & Automatic Sequencing

• Develop and commission line speed control, tension control, drive synchronization, and master‑follower strategies.
• Implement automatic sequences for coil loading, threading, welding, line acceleration, steady‑state processing, deceleration, recoiling, and coil unloading.
• Coordinate bridle rolls, pinch rolls, looper systems, strip accumulators, shears, welders, tension reels, and auxiliary equipment, as applicable.
• Troubleshoot speed mismatch, tension fluctuations, drive faults, sequence interruptions, and equipment interlocks.

E. Process Control & Equipment Integration

• Integrate furnace temperature and atmosphere control, strip cooling, coating and surface treatment systems, chemical dosing, and other process controls, according to line configuration.
• Interface with thickness gauges, flatness and shape measurement systems, coating weight gauges, welders, pyrometers, process analyzers, and other third‑party equipment.
• Develop and troubleshoot industrial communication interfaces using PROFINET, PROFIBUS, EtherNet/IP, OPC UA, Modbus TCP, and other applicable protocols.
• Integrate Level 1 automation with Level 2 process automation, including production recipes, coil tracking, process setpoints, material data, actual production feedback, and quality data exchange.

F. Commissioning & Site Leadership

• Execute FAT, SAT, I/O checks, functional testing, cold commissioning, dynamic testing, and production commissioning.
• Independently lead site commissioning teams and troubleshoot PLC, drive, instrumentation, process‑control, and communication issues.
• Coordinate with customers, vendors, subcontractors, and international engineering teams to achieve project milestones and customer satisfaction.
• Conduct site progress meetings, maintain Minutes of Meeting (MoM), track outstanding issues, and ensure timely punch‑point closure.
• Take end‑to‑end ownership of commissioning, performance validation, customer acceptance, final sign‑off, documentation, and formal site handover.

G. Engineering Documentation & Project Execution

• Prepare functional specifications, software design documents, interface specifications, test procedures, commissioning reports, and as‑built documentation.
• Maintain software revisions, backups, engineering change records, and technical documentation.
• Ensure engineering quality, technical compliance, and timely delivery of project milestones.

3. Essential Qualifications & Experience

• Minimum 10–15 years of relevant industrial automation and engineering experience, preferably in steel processing lines.
• B.E./B.Tech. in Electrical, Electronics, or Instrumentation Engineering.
• Strong hands‑on expertise in Siemens PLC programming, TIA Portal, STEP 7, and WinCC.
• Proven experience in processing line technology, strip tension control, drive coordination, automatic sequencing, and commissioning.
• Practical knowledge of Level 1/Level 2 integration, third‑party communication, and process automation.
• Demonstrated capability to manage engineering activities, independently lead commissioning teams, resolve complex technical issues, and achieve customer acceptance.
• C/C++ knowledge is desirable; ABB and Rockwell Automation experience is an advantage.