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Process Control & Development (PC&D) Automation Engineer Job Description
We are seeking a Process Control & Development Automation Engineer to join our Process Control & Development department at the Stainless Hot Rolling Mill. The engineer will be part of a team that is the custodian of the highly automated slab re-heating and hot rolling Level 2 modelling and some of the Level 1 control systems. The team maintains and improves these higher level "recipe" (Level 2) systems and some of the technology intensive lower level (Level 1) automated process control systems.
These systems include First Principal feed forward models and feedback control loops as well as Artificial Intelligence systems in the form of Fuzzy Logic Expert Systems and Neural Networks to ensure continuous process performance improvement. The ideal PC&D Engineer has a passion to automate processes and to improve process control to tight specifications, believing in the value of performance improvement through better automation.
At the highly automated Hot Mill, these automation upgrades will be based on world best practices in steel heating and rolling theory and principles. The engineer will study currently used modelling and control logic and do V software upgrades based on literature studies, own in-plant research, or as guided by PC&D management or other subject experts in the team.
The PC&D Engineer will own the outcomes of the software's effects on the product and process performance and will zealously improve these systems based on prioritised value-add needs of the Company. Additionally, the PC&D Engineer plans, directs, and co-ordinates hot rolling process improvements to affect quality, efficiency, and availability and maintains close control on critical product characteristics. The PC&D Engineer implements corrective and preventive actions to assure quality and effective process performance.
The engineer is responsible for investigating and assisting to reduce equipment failure in the incumbent's field of expertise.
Responsibilities
The incumbent will provide a service to the Business Unit in order to minimize delay times and enable the plant to perform at its maximum effectiveness at all times. It can be expected to investigate and solve problems as they occur. Services to the business unit include:
Identify problem areas requiring improvement as directed by business KPI's
Quantify the underlying contributory causes to the problems
Study the problem at the hand of the contributory causes and propose solutions
Implement solutions including automation, mistake proofing, and manufacturing procedures
Sustain and continuously improve performance through the automated systems and processes
Plan, direct, and co-ordinate hot rolling process improvements linked to PC&D systems to improve quality, efficiency, and availability
Investigate all modelling and control system failures and associated deviations to implement corrective and preventive actions
Implement solutions to assist with process and product development in association with Level 1 or 2, Technical and Production departments through consultation with other disciplines/departments
Maintain and develop the following systems:
Heat transfer modelling (finite element heat transfer Level 2 model) and combustion systems (Level 1)
Rolling modelling (Level 2): Speed, temperature, forces, torques and flatness control models (including neural network)
Level 1 thickness, flatness, strip cooling and coiling mostly feedback control systems
Expert System for continuous process parameter optimisation, of the heating and rolling processes (including Fuzzy Logic)
Weekly standby on a rotational basis with the other PC&D team members
Ensure compliance with the goals as defined in KPIs
Identify problems, investigate solutions, and solve problems in order to achieve those goals
Constantly co-ordinate process deviations with all relevant parties
React and correct all substandard process conditions
Qualifications
B Eng./ BSc. (Electrical, Electronic, Metallurgical or Mechanical) or Computer Science, Computer Engineering, or related field.
Skills and Experience
Experience in Software development (C, C++, C#, Visual Basic, Etc.) specifically in the engineering control software field
Knowledge of Level 2 type first principle models for heating and rolling technology
Knowledge of how these Level 2 models are automatically calibrated using artificial intelligence or other simpler methods
Knowledge of control systems and instrumentation is a plus
Creative and strong problem-solving and analytical skills
Experience working in a manufacturing or industrial environment is a plus
Enjoys working in the field of engineering solution development
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