Lead - Automation Engineer

JOB PURPOSE:

• Automation Engineers are vital members of the Process Automation & Control Systems team within the Process Automation organization.

• They play a critical role in designing, developing, and implementing advanced automation solutions to optimize the aluminum smelting process.

• Combining deep understanding of the smelting process with expertise in control systems, hardware, sensors, programming, logic development, automation, robotics, and software development, these engineers work to enhance process controllability, productivity, efficiency, environmental performance, and safety.

• They are expected to stay at the forefront of industry advancements, continuously seeking innovative ways to improve operations and working conditions by automating repetitive tasks and reducing operator exposure to harsh environments.

KEY ACCOUNTABILITIES:

Design and Development of Automation Systems:

• Lead the design and deployment of sophisticated automation systems and control architectures.

• Develop innovative control strategies and algorithms to improve process performance.

• Oversee the integration of advanced robotics and automation technologies into the production process.

• Develop and crosscheck prepared technical documentation related to R&D and industrial projects.

Process Understanding and Optimization:

• Develop and maintain a deep understanding of the aluminum smelting process, including multi-physics aspects such as thermodynamics, fluid dynamics, electromagnetism, and material science.

• Apply process knowledge to identify opportunities for automation and control improvements.

• Provide expert insights into process behavior and guide strategic decisions for process optimization.

• Mentor junior engineers in understanding the smelting and adjacent processes and applying it to automation projects.

Continuous Improvement and Innovation:

• Stay updated with the latest developments in automation, control systems, robotics, and related technologies.

• Propose and implement improvements to existing automation systems and processes.

• Drive innovation by introducing new technologies and methodologies.

• Lead research and development initiatives to advance the company’s automation capabilities.

Safety and Ergonomics Enhancement:

• Identify opportunities to automate repetitive or hazardous tasks to reduce operator workload and exposure to harsh environments.

• Ensure that automation solutions improve safety and ergonomics for operators.

• Lead initiatives to enhance workplace safety through automation.

• Develop strategies to remove operators from dangerous environments and improve working conditions.

Collaboration and Communication:

• Work collaboratively with cross-functional teams, including Process Engineers, Operations, Maintenance, and Digital Transformation.

• Communicate technical information effectively to team members and stakeholders.

• Lead cross-functional project teams.

• Present technical findings and proposals to senior management and stakeholders.

Project Management:

• Lead large-scale automation projects from conception to completion.

• Oversee project budgets, timelines, and resource allocation.

Compliance and Quality Assurance:

• Ensure that all automation solutions comply with industry standards, safety regulations, and company policies.

• Participate in testing, validation, and quality assurance processes.

Career Progression:

• Lead complex automation projects and strategic initiatives.

• Provide technical leadership and mentorship to the team.

• Influence technological advancements and contribute to organizational goals.

AUTHORITY/ DECISION MAKING:

• Lead the design and deployment of complex automation systems and control architectures.

• Make strategic decisions on automation architecture and technology adoption.

• Oversee the integration of automation systems with existing processes and peripheral equipment.

• Approve comprehensive automation project plans and ensure they meet technical and business objectives.

• Mentor junior automation engineers, guiding their decision-making and technical development.

QUALIFICATIONS & SKILLS:

Education:

• Bachelor’s or Master’s or Diploma’s degree in Electrical Engineering, Automation Engineering, Electronics Engineering, Control Systems Engineering, Chemical Engineering, Mechatronics, Computer Science, or a related field.

• Certificate of a high-level reduction process course (e.g., TMS, Electrolysis-III).

Experience:

• Over 8 years of experience in advanced automation and control systems.

• Demonstrated leadership in automation projects and team management.

Technical Skills:

Control Systems and PLC Programming:

• Proficiency with PLCs (e.g., Siemens, Allen-Bradley), HMIs, and SCADA systems.

• Knowledge of programming languages (e.g., ladder logic, structured text, C++, Python).

Hardware and Sensors:

• Experience with selecting and integrating sensors (e.g., temperature, pressure, flow sensors).

• Knowledge of instrumentation and data acquisition systems.

Robotics and Automation:

• Familiarity with robotics systems, including programming and integration.

• Understanding of motion control, actuators, and mechatronic systems.

Process Knowledge:

• Understanding of the aluminum smelting process and associated technologies.

• Knowledge of multi-physics aspects relevant to process automation.

Software Skills:

• Experience with automation software tools (e.g., TIA Portal, RSLogix, LabVIEW).

• Proficiency in CAD software for system design is a plus.

Soft Skills:

Analytical Thinking:

• Strong problem-solving abilities and analytical skills.

Communication:

• Effective verbal and written communication skills.

• Ability to convey technical concepts clearly.

Teamwork and Collaboration:

• Ability to work effectively in multidisciplinary teams.

• Willingness to share knowledge and support colleagues.

Project Management:

• Organizational skills to manage tasks and meet deadlines.

• For senior levels, ability to manage projects and lead teams.

Personal Attributes:

Innovation and Creativity:

• Enthusiasm for exploring new technologies and approaches.

Continuous Learning:

• Commitment to staying current with industry advancements.

Adaptability:

• Flexibility to adapt to changing project requirements and technologies.

Ethical Standards:

• Commitment to ethical practices and professional integrity.