Position Summary
Reporting directly to the Director of Maintenance & Engineering, the Engineering Manager provides strategic, technical, and operational leadership for the Engineering Department while serving as an essential partner to the Maintenance and Operations teams.
This position is responsible for leading the transformation to build the most automated extrusion plant in the United States by driving plant-wide automation modernization, controls standardization, and asset reliability. The Engineering Manager is directly accountable for optimizing Overall Equipment Effectiveness (OEE) through maximized control system reliability, refining manufacturing processes to increase recovery rates and throughput (Pounds Per Hour / PPH), and leveraging control system precision to minimize quality defects and scrap generation.
Essential Duties and Responsibilities
• Strategic Modernization & Obsolescence Elimination:
• Lead continuous plant modernization initiatives to eliminate obsolete PLCs, HMIs, drives, remote I/O systems, industrial network hardware, and field devices.
• Establish and execute long-term lifecycle management plans for all automation and electrical assets to mitigate operational risk across critical production lines.
• Platform Standardization & Controls Architecture:
• Enforce a unified “One Plant. One Architecture. One Standard” framework across the facility, standardizing plant-wide automation on the Allen-Bradley ecosystem (Studio 5000 logic, ControlLogix, CompactLogix, FactoryTalk View HMIs).
• Design, configure, and maintain robust plant-floor Operational Technology (OT) network architectures, including EtherNet/IP, Stratix industrial switching, CIP routing, and network segmentation.
• Standardize motion control platforms using Kinetix servo drives, synchronized multi-axis drive systems, variable frequency drives (VFDs), and standard safety circuit architectures.
• Intelligent Automation & Advanced Diagnostics:
• Deploy intelligent field technologies, expanding IO-Link architectures and modern distributed I/O (Flex 5000, Point Max I/O) to simplify wiring and shift diagnostics closer to field devices.
• Transform standard alarm matrices into actionable diagnostic systems that clearly communicate specific failure modes and exact physical locations (short circuits, open loops, overloads, actuator faults, communication loss).
• Implement condition monitoring and predictive health tracking across critical equipment (drive health, motor performance/vibration, temperature, and pneumatic/hydraulic monitoring).
• Program and standardize automated machine recovery routines, assisted restart workflows, and automated homing sequences to minimize recovery time after an outage.
• OEE, Throughput & Quality/Scrap Optimization:
•Optimize Overall Equipment Effectiveness (OEE) across all press and downstream lines by maximizing control system uptime and eliminating micro-stoppages (<10 minutes).
• Refine and optimize extrusion and downstream automated processes to drive higher recovery rates and continuously improve production throughput in Pounds Per Hour (PPH).
• Engineer tight control loop tolerances and closed-loop process parameters to minimize process variability, eliminate quality deviations, and significantly reduce operational scrap.
• Permanently eliminate PLC software bypasses, temporary electrical jumpers, and unauthorized workarounds to restore equipment strictly to OEM design performance.
• Lead structured Root Cause Analyses (RCA) on chronic breakdowns and quality excursions, deploying sustainable corrective actions.
• Maintenance Enablement & Documentation Integrity:
• Partner closely with Maintenance leadership to deploy intuitive diagnostic tools and visual troubleshooting aids that simplify fault isolation for technicians.
• Maintain up-to-date engineering archives, including electrical schematics, network topology drawings, PLC program backups, panel documentation, and I/O assignment records.
• Support workforce technical development to ensure maintenance personnel are capable of supporting both legacy and modern automation technologies.
• Department Leadership, Capital Execution & Compliance:
• Provide direct supervision, technical mentorship, and performance coaching to Controls Engineers, automation specialists, and technical electrical crews.
• Lead the planning, budgeting, engineering design, contractor oversight (electrical/mechanical), and commissioning of capital projects and major equipment overhauls.
• Ensure all engineering modifications and installations comply with plant safety requirements, OSHA standards, ISO 9001 quality documentation, and local electrical/building codes.
Job Requirements
• Education: Bachelor’s Degree in Electrical Engineering (BSEE) or related electrical engineering discipline required.
• Industrial Experience: Minimum 5+ years of engineering experience in heavy manufacturing, metals, extrusion, or continuous industrial processing environments.
• Supervisory Leadership: Minimum 5+ years of direct leadership and supervisory experience managing Controls Engineers, automation specialists, and technical electrical maintenance crews.
• Automation & OT Network Mastery:
• Advanced programming, design, and troubleshooting proficiency with Allen-Bradley PLCs (Studio 5000, ControlLogix, CompactLogix) and FactoryTalk View HMIs.
• Hands-on technical expertise in multi-axis motion control utilizing Kinetix servo drives and coordinated drive systems.
• Proven working knowledge of industrial Operational Technology (OT) networks (EtherNet/IP, Stratix switches, network segmentation, and CIP routing).
• Process Optimization & Scrap Reduction: Proven track record in optimizing OEE, driving Pounds Per Hour (PPH) throughput, maximizing material recovery, and utilizing automated controls to reduce scrap and defects.
• Mechanical, Fluid & Thermal Systems Comprehension: Strong working knowledge of heavy industrial hydraulics, high-pressure pneumatics, mechanical power transmission (gearboxes, drivetrains), and thermal/combustion processing equipment.
• Project Delivery & Execution: Demonstrated track record in capital budget management, outage/shutdown planning, contractor trade management (cabling, conduit, mechanical installation), and systematic root-cause problem solving (RCA).