Process Controls Programmer

Rockline Industries, people who make it right; Morristown (TN); On-site; USD 65,000 - 90,000; Full time

Job summary

Rockline Industries in Morristown, TN is seeking an Engineer I – Process Controls Programmer to support programming, troubleshooting, and maintenance of Rockwell Automation PLC/PC-based control systems across chemical mixing, blending, and transfer processes.

You will collaborate with Engineering, Operations, Quality, Maintenance, and IT/OT teams to implement control system improvements, document changes, and ensure compliance with safety and regulatory standards.

Qualifications

• Bachelor’s degree in electrical/controls/automation engineering or related field.
• Understanding of PLCs, HMIs, motor controls, and industrial networking.
• Ability to read electrical drawings, P&IDs, control narratives, and I/O lists.
• Knowledge of process control concepts: batching, sequencing, alarms, interlocks.
• Willingness to learn Rockwell Automation PLCs, FactoryTalk, and batch control systems.
• Proficient with MS Excel and engineering software tools.
• Strong written, verbal, and interpersonal communication skills.

Responsibilities

• Modify, troubleshoot, and write PLC, HMI, VFD, and related control programs for chemical processes.
• Create electrical schematics, control narratives, I/O documentation, and process documentation.
• Research control process improvements and equipment within Chem Mix.
• Assist in installation, commissioning, and support of automation changes.
• Test, commission, and validate programming changes.
• Troubleshoot root causes affecting batch quality and line performance.
• Maintain machine and process safety systems and interlocks.

Skills

PLC programming

HMI development

Instrumentation

Control systems

Electrical schematics

Problem-solving

Documentation

Engineering software

Education

Bachelor’s degree in Electrical/Controls/Automation Engineering

Equivalent combination of education and experience

Tools

Rockwell Automation PLCs

FactoryTalk

Batch control systems

Job description

The Engineer I - Process Controls Programmer provides programming, troubleshooting, maintenance, and improvement support for FactoryTalk Batch and related automation systems used in manufacturing operations. This role supports chemical mixing, blending, batching, transfer, cleaning, and sanitizing processes to ensure safe, reliable, and efficient production. The Engineer I – Process Control Programmer assists with the configuration, modification, testing, documentation, and commissioning of PLC, HMI, VFD, instrumentation, and batch control systems. The role partners with Engineering, Operations, Quality, Maintenance, EHS, and IT/OT teams to implement control system improvements, support new products and process changes, resolve automation issues, and maintain compliance with established standards and regulatory requirements. Participates in continuous improvement initiatives and supports automation projects of increasing complexity while developing expertise in batch control systems and ISA-88 principles.

Essential Accountabilities

• Modify, troubleshoot, and write PLC, HMI, VFD, instrumentation, and related control programs for chemical mixing, blending, batching, and transferring of wet wipe manufacturing processes.
• Collaborate and create electrical schematics, control narratives, I/O documentation, and process documentation related to chemical mix/blending process.
• Research and identify control process improvements, formula changes, and new chemical blending equipment within Chem Mix.
• Assist in installation, commissioning, and support of automation changes on new and existing chemical mixing and blending equipment.
• Perform testing, commissioning, and validation of programming changes on new and existing projects and programming changes within Chem Mix.
• Troubleshoot and determine root cause analysis for controls-related issues affecting chemical mix quality, batch repeatability, equipment uptime, chemical delivery, line performance, and operator interface usability.
• Creates standard work procedures for the Chemical Mix process.
• Identify required controls and instrumentation critical spare parts and aid leadership and the parts department in maintaining a critical spare parts listing.
• Update and create recipe/change documentation and related process documentation for new and existing chemical mixing and blending systems
• Serves as the liaison between the plant and Global Engineering.
• Coordinate small scale tasks for hired contractors and services.
• Maintain, troubleshoot, and update machine and process safety systems, including interlocks, permissive, alarms, emergency stops, guarding circuits, and controls related to safe chemical handling and equipment operation.
• Demonstrate commitment to company RRITE Values of Renew, Respect, Integrity, Teamwork, and Excellence.
• Associates have a direct and important role in ensuring that all work is performed in a safe manner. Effectiveness in carrying out this responsibility is part of each associate’s essential accountabilities.
• Contribute to a cooperative working effort by demonstrating a willingness to perform other job-related work, as needed or requested.

This position is designated as Safety-Sensitive (A safety-sensitive position is one in which the associate’s inability or impaired ability to perform their job-related tasks could result in a direct threat to the associate’s safety or the safety of others).

QUALIFICATION REQUIREMENTS

• Bachelor’s degree in Electrical Engineering, Controls Engineering, Chemical Engineering, Automation Engineering, Computer Engineering, or related technical discipline.

An equivalent combination of education and relevant experience may be considered.

• Basic understanding of industrial automation and control systems, including PLCs, HMIs, instrumentation, motor controls, and industrial networking concepts.
• Exposure to manufacturing processes, process controls, or industrial automation through coursework, internships, co-op assignments, or prior experience.
• Ability to read and interpret electrical drawings, P&IDs, control narratives, I/O lists, and basic process documentation.
• Fundamental understanding of process control concepts such as batching, sequencing, alarms, interlocks, flow control, level control, temperature control, and recipe management.
• Ability to learn automation platforms such as Rockwell Automation PLCs, FactoryTalk applications, and batch control systems under the guidance of senior engineers. Strong analytical and problem-solving skills with the ability to learn and apply engineering principles in a manufacturing environment.
• Willingness and ability to participate in troubleshooting, testing, commissioning, documentation, and continuous improvement activities Basic knowledge of computer applications including Microsoft Excel, Word, PowerPoint, and other engineering software tools.
• Demonstrated written, verbal, and interpersonal communication skills.