Automation Engineer

Position Summary:

We are seeking a highly motivated Automation Engineer to join our team at an alumina refinery. This role is critical in providing technical support to manufacturing, the repair of automation equipment, and executing capital and improvement projects. They will apply engineering principles to identify Control System improvements that ultimately improve efficiency and reduce operational cost. The successful candidate will lead root cause analysis (RCA) for equipment failures, champion continuous improvement initiatives, and manage projects using the Front-End Loaded (FEL) process.

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Key Responsibilities:

- Monitor and improve the OEE of Plantwide Automation systems

- Perform trouble shooting of process control systems in Atalco manufacturing operations. Identify problems and complete repairs and or replacement of parts.

- Maintain, update, and develop improvements to existing DCS, PLC, and Network systems that improve operating efficiencies of Atalco.

- Maintain and develop improvements to Aveva PI data archive system.

- Develop and deliver training to maintenance engineers, E/I technicians, and manufacturing operators on modified and/or new controls.

- Investigate control system malfunctions and Hazop incidents, collect data, write final reports, and lead in development of corrective actions.

- Root Cause Analysis (RCA):

- Lead investigations into equipment failures and chronic reliability issues.

- Facilitate cross-functional RCA sessions and develop actionable recommendations.

- Track and report on corrective actions and effectiveness.

- Management of Change (MoC):

- Own and lead or participate in the MoC process for mechanical systems and equipment modifications.

- Ensure compliance with safety, environmental, and operational standards.

- Collaborate with operations, maintenance, and engineering teams to assess risks and impacts.

- Continuous Improvement:

- Identify improvement opportunities, prepare business cases and execute change as per the FEL process.

- Utilize field data collection and analysis to identify failure trends and reliability opportunities.

- Develop and implement strategies to eliminate repeat failures and improve equipment uptime.

- Support reliability-centered maintenance (RCM) and predictive maintenance programs.

- Project Management (FEL Process):

- Lead automation projects from concept through execution using the FEL methodology.

- Develop scopes, budgets, schedules, and risk assessments for capital and improvement projects.

- Coordinate with internal stakeholders and external contractors to ensure successful project delivery.

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Key Performance Indicators (KPIs):

- RCA Effectiveness:

- % of RCAs completed within target timeframe.

- % of corrective actions implemented and verified.

- Reduction in repeat failures of critical equipment.

- MoC Compliance:

- % of MoC processes completed on time.

- Number of MoC-related incidents or deviations.

- Audit compliance score for MoC documentation.

- Reliability & Uptime:

- Mean Time Between Failures (MTBF) for key assets.

- % reduction in unplanned downtime.

- % improvement in equipment availability.

- Project Execution:

- % of projects delivered on time and within budget.

- FEL stage gate compliance rate.

- Stakeholder satisfaction score (post-project reviews).

- Continuous Improvement:

- Number of CI initiatives implemented annually.

- Estimated cost savings or value creation from CI efforts.

- % of field data collection targets achieved.

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Qualifications:

- Bachelor’s degree in Engineering or related field.

- 6-10+ years of experience in heavy industrial environments, preferably in alumina or similar refining operations.

- Experience working with ABB, Allen Bradley, Triconex, and Aveva systems.

- Proven experience in RCA, MoC, and project management.

- Strong analytical and problem-solving skills.

- Advanced knowledge in networking systems.

- Excellent communication and leadership skills.

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Preferred Skills:

- Certification in reliability engineering (e.g., CMRP).

- Experience with FEL project methodology.

- Knowledge of alumina refining processes and equipment.