Automation Engineer

Sonoco; Chesterfield (MO); On-site; USD 70,000 - 90,000; Full time

Job summary

Sonoco is seeking an Automation Systems Engineer at our Chesterfield plant to enhance the efficiency of manufacturing processes through automation. You will collaborate with the engineering and production teams, providing technical support and leading projects to improve equipment and control systems.

The ideal candidate will have a degree in Electrical Engineering and proven experience with Siemens and Allen-Bradley technologies. This role requires excellent problem-solving skills and the ability to train others in automation techniques.

Qualifications

• Proven knowledge and experience in Siemens S5, S7, Allen‑Bradley.
• 2 years or more of experience in a process-control/engineering role.
• Experience in an FMCG environment.

Responsibilities

• Provide technical support across electrical, mechanical and automation disciplines.
• Coordinate site automation projects and ensure compliance with current legislation.
• Develop and install new hardware or software to improve system functionality.

Skills

Problem solving

Excellent communication skills

Ability to analyze complex data sets

Training and coaching

Control systems knowledge

Education

HNC/Degree in Electrical Engineering

Graduate Masters/Bachelor in a Technical/Manufacturing/Sciences subject

Tools

Siemens S5

Allen-Bradley systems

AutoCad

Job description

What We Do

At Sonoco Chesterfield we manufacture composite cans used as packaging mainly for food and powdered beverages.

You have probably seen some of our products on the shelves in the supermarket: Pringles, the nation’s favourite Bisto, Nestlé Coffee Mate, SlimFast powdered beverages, Heinz Baby Food, etc… We are aiming to be one of the first fully paperboard cylindrical packing suppliers, where our packaging is durable and 100% recyclable.

Purpose of the 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

Supporting the production and engineering team through line breakdowns, aiding fault‑finding of the root cause and designing the issue out in the shortest period possible. You’ll be supported by the shift‑engineer team, the process‑improvement engineers and our operators. Running automation projects to plan for continued upgrades of equipment and control systems, ensuring none of our equipment becomes obsolete or out of date.

Additional Activities & Projects

You will also be involved in projects and day‑to‑day activities at our sister site in Bradford. 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 product launch support at manufacturing level.

Role within the Company & Stakeholder Interactions

The candidate will report to the site Engineering Manager and interact daily with Manufacturing, Engineering, Warehouse, Supply Chain, sister plants (in Europe) and suppliers. The Automation Systems Engineer is expected to be a subject‑matter expert and mentor engineers within the business.

Key Activities

• Provide technical support to all areas daily across electrical, mechanical and automation disciplines.
• Configure and program controllers and visualisation systems using Siemens (Simatic Manager, TIA Portal and WinCC flexible software).
• Plan and program drive technology and servo drives – emphasising SEW Drive and Allen‑Bradley systems.
• Develop, conceive, design and create hardware and circuit diagrams.
• Perform automation troubleshooting following a recognised process.
• Experience with bus systems and bus technology such as “Profinet” and “Profibus” and knowledge of ASI bus and CAN bus.
• Project‑manage and coordinate site automation projects.
• Use AutoCad/Cad systems to maintain documentation updates and produce 2D CAD drawings of control panels, P&IDs and electrical wiring diagrams.
• Provide onsite services for start‑up or troubleshooting.
• Support and lead automation activities at both the Chesterfield and Bradford production sites.
• Develop HMIs for operator use.
• Coordinate with cross‑functional teams to resolve automation issues.
• Write programs for newly designed automatic and semi‑automatic machines and conveyor systems for Siemens and Allen‑Bradley hardware.
• Debug and test new or modified PLC and robotic programmes on the production floor.
• Conduct comprehensive machine and system testing.
• Ensure the department operates in accordance with current legislation, company and statutory requirements.
• Ensure the safe and efficient operation of equipment throughout the site.
• Install production and plant equipment, commission, analyse breakdowns and perform repairs.
• Identify areas for engineering improvements to increase safety, quality, efficiency or reduce waste.
• Assist with training company apprentices and shift engineers.
• Assist in developing operational manuals for newly designed machines and conveyor systems.
• Assist in risk assessment of newly designed machines, emphasising machine safety.
• Help refine and develop programming standards and methods.
• Coordinate with other engineers and programmers on large systems and machines.
• Maintain and enhance software and robotics solutions for the two sites.
• Document software changes and updates to support equipment modifications and continued operation.
• Work with Manufacturing/Operations to identify and troubleshoot machine control failures.
• Specify instrumentation and control hardware for equipment upgrades and future lines.
• Stay abreast of new technology and advise the site accordingly.
• Run testing and diagnostics on IT systems to identify potential problems.
• Identify and resolve malfunctions within the system.
• Develop and install new hardware or software to improve system functionality.
• Liaise with outside suppliers or developers to source effective hardware or software for the company’s needs.
• Create schematic plans of the system.
• Build robust backups accessible in the event of system failure.
• Train shift engineers and process‑improvement engineers to work within the systems and resolve issues independently.
• Liaise with operational staff to ensure systems complete designed tasks.
• Lead improvement activities and projects across the 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

Qualifications and Experience

Required

• HNC/Degree qualified Electrical Engineering
• Proven knowledge and experience in Siemens S5, S7, Allen‑Bradley (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 analyze complex data sets quickly.
• Prioritize 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 drive for continuous improvement.
• Excellent team player with good interpersonal skills, able to communicate at all levels.
• Logical with keen eye for detail.
• Excellent customer focus required.
• Willing to travel within the UK and Europe.

Working Environment

The position is based in the Chesterfield plant but may require visits to our manufacturing plants in the UK and Europe as well as suppliers or customers in the UK.

Equal Opportunity Statement

We are an equal‑opportunity employer and strictly prohibit discrimination against employees, applicants or any other covered persons because of race, colour, religion, national‑origin or ancestry, sex, pregnancy, sexual orientation, marital status, gender identity or expression, age, disability, genetic information, veteran status or any legally protected characteristic.