Operations & Controls Engineer

As an Operations & Controls Engineer, you will oversee the maintenance, functionality, and calibration of laboratory equipment and testing instruments. You'll manage maintenance schedules, investigate equipment issues, troubleshoot faults in PLC-controlled systems, and support automation integration. Your role will involve close cooperation with production, IT, and engineering teams, leading improvement projects to increase efficiency and testing quality while ensuring compliance with safety standards.

To qualify for the Operations & Controls Engineer role, candidates should possess a Bachelor’s degree in Electrical, Mechanical, Mechatronics, or a related engineering field, alongside a minimum of 3 years of experience in an engineering or lab automation environment. Proficiency in electrical troubleshooting, PLC logic, and HMI/SCADA systems is essential. Additionally, strong communication skills and the ability to manage multiple tasks independently are important.

The Operations & Controls Engineer plays a crucial role in continuous improvement by leading projects aimed at enhancing lab processes and control systems. You will be responsible for identifying solutions to improve real-time troubleshooting, minimizing downtime, and working with IT and software support to monitor system performance. Your innovative ideas will help drive the overall efficiency and reliability of our testing operations.

Relevant experience with PLC systems is pivotal for an Operations & Controls Engineer. Familiarity with platforms such as Honeywell or AutomationDirect, proficiency in programming and troubleshooting PLC control logic, and experience with industrial communication protocols are highly beneficial. Hands-on experience with SCADA/HMI software additionally enhances your capability to integrate lab automation effectively.

Working conditions for the Operations & Controls Engineer position may involve exposure to dusty or noisy environments typical of a lab setting. The role requires fieldwork with regular exposure to test equipment and utilities, and physical requirements include frequent standing, walking, and the ability to lift up to 40 pounds. While it’s a hands-on role, there will also be computer work involved for project management and documentation.

When answering this question, detail your proficiency with various PLC platforms, providing examples of how you've programmed, maintained, and optimized control logic in previous roles. Discuss specific projects where your PLC skills directly improved lab processes or efficiencies.

In your response, share a specific instance of a troubleshooting challenge you encountered, emphasizing your problem-solving process. Discuss the tools and techniques you used to identify the issue, and explain how you collaborated with team members to resolve it efficiently.

Explain your approach to maintaining safety standards by detailing your knowledge of laboratory safety protocols. Share specific practices you implement to ensure compliance during laboratory processes and how you educate team members about safety measures.

Discuss your methods for prioritizing maintenance tasks, such as assessing equipment condition, analyzing historical data on equipment failures, and aligning with operational priorities. Highlight how you communicate with team members to ensure timely maintenance while minimizing disruptions.

Describe your collaborative strategies, including how you initiate discussions to identify process improvement needs, share insights from your engineering perspective, and work together with IT to integrate software solutions that enhance testing efficiency.

In your response, talk about the importance of clear documentation and the specific tools you use for creating IO maps, control sequences, and automation workflows. Emphasize how thorough documentation aids in accountability and facilitates training for new team members.

Share a detailed example of a project where you led a process improvement initiative. Discuss the challenges you faced, the strategies you applied to overcome them, and the positive outcome achieved, backed by measurable results if possible.

Talk about your commitment to continuous professional development, including specific training programs, certifications, or industry conferences you regularly attend. Highlight how staying updated on trends contributes to your effectiveness as an Operations & Controls Engineer.

Discuss your approach to conflict resolution, focusing on communication, flexibility, and prioritization. Explain how you would assess the importance of each task and strategize to balance workload while keeping team members informed.

Specify the tools and software you are comfortable using for PLC troubleshooting and HMI development. Be sure to mention any relevant experience you have with specific products or brands, and how these tools have facilitated your efficiency in past roles.