Principal - Automation Engineer

About Emirates Global Aluminium

Emirates Global Aluminium is the world’s biggest ‘premium aluminium’ producer and the largest industrial company in the United Arab Emirates outside the oil and gas industry.  EGA is an integrated aluminium producer, with operations on four continents from bauxite mining to the production of cast primary aluminium and recycling. EGA employs over 7,000 of these people including more than 1,200 UAE Nationals. EGA operates aluminium smelters in Jebel Ali and Al Taweelah in the United Arab Emirates, an alumina refinery in Al Taweelah, a bauxite mine and associated export facilities in the Republic of Guinea, a speciality foundry in high strength recycled aluminium in Germany, and a recycling plant in the United States.

JOB PURPOSE:

• Leads the Process Automation & Control Systems team within the Process Automation organization, reporting directly to the Manager of Process Automation.

• Plays a pivotal role in driving the development and implementation of advanced automation solutions for the aluminum smelting process.

• Combines strong technical expertise in hardware, sensors, electronics, PLC programming, and robotics with a deep understanding of the smelting process, its operation, maintenance, and control systems.

• Manages both R&D and industrial projects, oversees CAPEX/OPEX budgets, leads project management efforts, and fosters relationships with suppliers.

• Spearheads the industrialization of new capabilities into the control system of reduction cells and automates interfaces with peripheral equipment such as PTMs (Pot Tending Machines) and vehicles.

KEY ACCOUNTABILITIES:

Technical Leadership:

Automation and Control Systems Development:

• Lead the design, development, and implementation of automation and control systems for the smelting and adjacent processes.

• Oversee the integration of advanced sensors, hardware components, and new control logics to optimize process performance.

Process Understanding:

• Develop and maintain a deep understanding of the aluminum smelting process, including operation, process control, and maintenance aspects.

• Apply process knowledge to enhance automation solutions and improve efficiency.

Project Management:

R&D and Industrial Projects:

• Manage and lead both R&D projects for fast-developing technologies and systematic industrial projects for large-scale implementations.

• Employ agile methodologies for R&D setups and systematic approaches for industrial systems development.

CAPEX/OPEX Management:

• Prepare and manage budgets for projects, ensuring optimal allocation of CAPEX and OPEX resources.

• Monitor project expenditures and adjust plans as necessary to meet financial targets.

Timeline and Resource Management:

• Develop project plans with clear milestones and deliverables.

• Allocate team members effectively to meet project priorities and deadlines.

Team Leadership and Development:

Team Management:

• Lead a multidisciplinary team of engineers with various specializations such as hardware and electronics design, programming, robotics, etc.

• Foster a flexible team environment where members can move between areas based on project needs.

Skill Development:

• Encourage continuous learning and professional growth within the team.

• Promote staying updated with the latest developments in hardware, software, sensors, control, and automation industries.

Collaboration:

• Work closely with other teams and departments, including Modelling, Technology Engineering, Operations, Maintenance, and Digital Transformation.

• Facilitate strong collaboration within the team and with other departments, such as Technology Transfer and Digital Transformation, during industrial implementations.

Industrialization and Implementation:

Control System Enhancements:

• Lead the industrialization of new capabilities into the control system of reduction cells.

• Develop automation solutions for peripheral equipment interfaces, including PTMs and vehicles.

Technology Transfer Collaboration:

• Work closely with the Technology Transfer team to implement industrial designs for external clients.

• Ensure seamless transition from R&D projects to full-scale industrial applications.

Supplier and Stakeholder Management:

Supplier Relationships:

• Manage relationships with suppliers of hardware, software, sensors, and other equipment.

• Negotiate contracts, oversee procurement processes, and ensure timely delivery of components.

Stakeholder Communication:

• Communicate effectively with internal and external stakeholders, including senior management, clients, and cross-functional teams.

• Present project updates, technical findings, and recommendations.

Innovation and Continuous Improvement:

Technology Scouting:

• Stay abreast of industry trends, emerging technologies, and advancements in automation and control systems.

• Evaluate new technologies for potential applications in the smelting and adjacent processes.

Process Optimization:

• Identify opportunities for improving process efficiency, safety, and environmental performance through automation.

• Implement innovative solutions to enhance operational excellence.

Technical Documentation and Reporting:

Documentation:

• Prepare detailed technical documentation, including specifications, functional requirements, manuals, instructions, and guides.

• Maintain comprehensive records of development activities and changes.

Reporting:

• Provide regular updates on projects progress and technical challenges.

Compliance and Quality Assurance:

Regulatory Compliance:

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

Quality Control:

• Implement quality assurance processes to maintain high standards in design, development, and implementation.

• Implement rigorous testing and validation procedures to verify the accuracy and reliability of new or modified applications or control logics.

• Conduct risk assessments and implement mitigation strategies.

Health, Safety, and Environment (HSE):

• Promote and adhere to HSE policies and practices.

• Ensure all projects prioritize safety and environmental sustainability.

AUTHORITY / DECISION MAKING:

Team Leadership:

• Authority to lead the Process Automation & Control Systems team, making key decisions on automation system designs and implementations.

• Approve project plans, budgets, and resource allocations for automation projects.

System Integration:

• Make critical decisions regarding the integration of hardware, sensors, electronics, and robotics into control systems.

• Oversee the automation of peripheral equipment interfaces (e.g., PTMs, vehicles), ensuring seamless integration and optimal performance.

Supplier Management:

• Manage relationships with suppliers, negotiating contracts and making decisions on procurement of automation components.

• Approve vendor selections and oversee supplier performance to ensure quality and timely delivery.

Project Approval:

• Lead the development and approval of automation project documentation, ensuring compliance with technical and safety standards.

• Make decisions on the adoption of new automation technologies and methodologies to enhance process controllability and efficiency.

Strategic Decision-Making:

• Make strategic decisions on automation architecture and technology adoption to align with organizational goals.

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

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:

• Minimum of 10 years of experience in automation and control systems engineering within an industrial environment.

• Proven experience in leading multidisciplinary engineering teams.

• Extensive experience in managing large-scale projects, including R&D and industrial implementations.

• Demonstrated expertise in CAPEX/OPEX management and supplier relations.

Technical Skills:

Automation and Control Systems:

• Proficiency in the automation and control systems development such as PLC, HMI, DCS, and SCADA.

• Strong knowledge of hardware integration, sensors, electronics, and robotics.

Process Knowledge:

• Deep understanding of the aluminum smelting process, including operational and maintenance aspects.

• Familiarity with process control strategies and techniques.

Software Development:

• Experience with programming languages relevant to automation (e.g., Ladder Diagram, Structured Text, C/C++, etc.).

• Familiarity with PLC, HMI, and SCADA programming tools.

• Knowledge of industrial communication protocols (e.g., Modbus, Profibus, Ethernet/IP).

Project Management Tools:

• Experience in project management software and tools such as MS Project, etc.

• Familiarity with agile methodologies and practices.

Soft Skills:

Leadership:

• Strong leadership abilities to inspire and guide a diverse engineering team.

• Ability to foster a collaborative and innovative team culture.

Communication:

• Effective verbal and written communication skills.

• Ability to present complex technical information clearly to various audiences.

Analytical Thinking:

• Strong problem-solving skills with the ability to analyze complex systems and processes.

• Detail-oriented with a focus on quality and precision.

Adaptability:

• Flexibility to adapt to changing project requirements and industry developments.

• Ability to manage multiple projects simultaneously.

Personal Attributes:

Innovation:

• Passion for exploring new technologies and driving innovation.

Integrity:

• Commitment to ethical practices and professional integrity.

Motivation:

• Self-motivated with a strong drive to achieve results and exceed expectations.

Continuous Learning:

• Dedication to ongoing professional development and staying current with industry trends.