Role and Responsibilities
Automation & Control System Ownership
- Own PLC, Ignition SCADA, HMI, drives, communication networks, and plant control system performance.
- Maintain control system architecture, standards, documentation, and backups.
- Ensure automation systems are stable, reliable, and maintainable.
- Maintain proper program backup, version control, and change records.
- Identify obsolete or high-risk automation components and recommend upgrade plans.
PLC Programming & Troubleshooting
- Perform independent troubleshooting on PLC and control system faults.
- Develop, modify, test, and optimize PLC programs.
- Diagnose automation-related equipment trips and recurring faults.
- Review and improve control logic to increase equipment reliability and production stability.
- Ensure all PLC changes are tested, backed up, documented and approved before implementation.
Ignition SCADA Development & Support
- Develop, modify, troubleshoot, and maintain Ignition SCADA applications.
- Troubleshoot communication between PLC, Ignition SCADA, field devices, and related systems.
- Develop and maintain:
- SCADA screens and navigation
- Tags
- Alarms
- Trends and historical data
- Recipes
- User access and permissions
- Equipment status and production monitoring
- Support integration of new equipment into Ignition SCADA.
- Diagnose and resolve SCADA communication, tag, alarm, scripting, and system-performance issues.
- Maintain Ignition Gateway configuration, backups, and system documentation.
- Support future migration of legacy control/SCADA systems to Ignition where required.
Automation Breakdown Support & RCA
- Provide technical support for automation-related breakdowns.
- Troubleshoot PLC, SCADA, HMI, VFD/inverter, communication, instrumentation, and control-system failures.
- Work with Maintenance Supervisor and technicians during equipment breakdowns.
- Lead root cause analysis (RCA) of automation and control system failures, implement sustainable corrective actions, and drive continuous improvement initiatives to enhance system reliability and prevent recurring breakdowns.
- Provide remote or onsite support for critical automation breakdowns when required.
- Provide end-to-end technical support by resolving issues internally while ensuring timely engagement of external technical support for issues beyond organization's expertise.
Industrial Communication & System Integration
- Troubleshoot industrial communication networks and device integration.
- Support systems using protocols/networks such as:
- PROFINET / PROFIBUS
- Ethernet/IP
- Support integration between PLC, SCADA, HMI, VFD, weighing/feeding systems, and other production equipment.
- Diagnose communication loss, network faults, and device connection issues.
Automation Projects & Management of Change
- Lead automation-related improvement and upgrade projects.
- Develop control-system concepts and logic requirements.
- Prepare automation project scope and technical requirements.
- Support equipment installation, commissioning, FAT and SAT.
- Prepare and maintain MOC documentation for control-system changes.
- Conduct or support risk assessment for automation modifications.
- Ensure automation changes are tested, validated, backed up, documented, and approved before implementation.
- Coordinate with Maintenance Engineer, Production, vendors, and Corporate Engineering.
Automation Safety & Compliance
- Ensure automation modifications comply with company and regulatory safety requirements.
- Validate alarms, interlocks, permissive, and control sequences.
- Ensure control-system changes do not bypass or compromise machine safety.
- Support risk assessment for automation-related modifications.
- Ensure contractors follow applicable company safety requirements.
Documentation & System Backup
- Maintain current PLC, HMI, SCADA and drive program backups.
- Maintain control-system drawings and relevant technical documentation.
- Maintain change history and version control.
- Document troubleshooting solutions for recurring faults.
- Maintain equipment communication and control-system information for future troubleshooting.
Training & Knowledge Transfer
- Provide basic PLC, SCADA and automation troubleshooting training to maintenance technicians.
- Develop troubleshooting guides for common automation problems.
- Provide technical guidance and transfer knowledge to Maintenance Engineers, Supervisors, and Technicians to support skills development and continuous improvement.
- Build internal automation troubleshooting capability.
Continuous Improvement
- Identify opportunities to improve automation reliability, productivity, quality and efficiency.
- Support Kaizen and plant improvement activities.
- Recommend automation upgrades where existing systems are obsolete or unreliable.
- Drive initiatives to reduce automation-related equipment downtime and optimize maintenance costs.
On-Call & Emergency Support
- Provide timely on-call support for critical automation incidents to minimize production downtime and ensure operational continuity.
- Provide remote or onsite troubleshooting support.
- May be required to work beyond normal working hours or weekends based on operational needs.
Education Qualification
- Bachelor's Degree or Diploma in Automation, Electrical, Electronics, Mechatronics, Control Engineering, or related field.
- Relevant automation or Ignition certification would be an advantage.
- Candidates with equivalent technical qualifications and/or relevant hands-on experience will also be considered.
Work Experience
- Preferably 5+ years of industrial automation experience in a manufacturing environment.
- Demonstrate strong hands-on and practical experience in PLC programming, troubleshooting, and system modifications, including fault diagnosis of PLC I/O, HMI, control logic, alarms, interlocks, industrial communication networks, and PLC/SCADA system integration.
- Ability to read, interpret, and troubleshoot electrical schematics, wiring diagrams, and control circuits to support effective equipment maintenance and reliability.
- Experience with HMI, motor drives, industrial communication, and system integration is preferred.
Other Requirements
- Strong hands-on troubleshooting and problem-solving capability.
- Able to independently diagnose and resolve automation and control system issues.
- Strong ownership and accountability for automation system performance and reliability.
- Able to work effectively with Maintenance, Production, Engineering, and external vendors.
- Able to prioritize and manage multiple breakdown issues, action items, and improvement activities.
- Good communication and technical documentation skills.
- Continuously improve technical capability and keep up to date with Ignition SCADA and industrial automation technologies.