Lead - Automation & Controls

Job Summary:

As the Controls and Automation Engineering Lead in the Li-Ion Battery Manufacturing industry, you will lead the design, development, and implementation of automated control systems to optimize production processes, ensuring high efficiency, quality, and safety. This role is pivotal in overseeing the engineering team responsible for controls, automation systems, and process control technologies. The ideal candidate will have a strong background in process automation, PLCs, SCADA, HMI, Vision Controls, and other control systems, with experience in developing the architecture for PLC, HMI, IPC, communication protocols, MES (Manufacturing Execution Systems), and PLM (Product Lifecycle Management) integration. You will manage large-scale automation projects and lead a team of engineers to drive improvements in manufacturing operations.

Key Responsibilities:

• Leadership and Team Management: Lead, mentor, and manage a team of control and automation engineers. Develop a high-performing team by providing technical guidance and promoting professional development.
• Control Systems Design: Oversee the design, programming, testing, and implementation of control systems (PLC, SCADA, HMI, DCS, etc.) for manufacturing processes in the Li-Ion Battery production line.
• Architecture Development: Design and develop the architecture for PLC, HMI, IPC, and related control systems, ensuring seamless integration with plant equipment, automation systems, and other technologies.
• Automation System Development: Lead the automation efforts across the plant, ensuring that all automation systems (including robotics, material handling systems, process controls, and Vision Controls) are aligned with production objectives and efficiency targets.
• Vision Control Systems: Develop and implement Vision Control Systems for quality inspection, material tracking, and defect detection within the manufacturing process. Ensure integration of vision systems with other automation and control systems to improve manufacturing consistency and reduce errors.
• Communication Protocols: Develop, configure, and manage communication protocols (e.g., OPC, MQTT, Modbus) to ensure seamless and reliable data exchange between PLCs, HMIs, IPCs, and other systems across the production line.
• System Integration: Integrate control systems with other enterprise systems such as MES (Manufacturing Execution Systems) and PLM (Product Lifecycle Management), ensuring real-time data exchange for improved decision-making, traceability, and quality control.
• Process Optimization: Continuously evaluate and improve control systems and automated processes to optimize production efficiency, reduce downtime, and ensure seamless integration with plant operations.
• Project Management: Manage and deliver large-scale automation projects from design through implementation. Ensure that projects are completed on time, within budget, and meet quality standards.
• Troubleshooting and Support: Provide technical support for troubleshooting and resolving complex automation issues, working closely with other departments, such as maintenance and production.
• Continuous Improvement: Implement continuous improvement initiatives to increase the automation systems' reliability, accuracy, and performance, and to optimize energy efficiency and reduce operational costs.
• Compliance and Standards: Ensure all control systems and automation processes adhere to industry regulations, safety standards, and environmental compliance requirements.
• Documentation and Reporting: Maintain thorough documentation for all control systems, including user manuals, technical specifications, and system operation procedures. Prepare reports for management on automation system performance and improvement initiatives.
• Collaboration with Cross-Functional Teams: Work closely with cross-functional teams including operations, engineering, and IT to ensure that control systems and automation are integrated seamlessly into the overall manufacturing process.
• Training and Development: Develop and deliver training programs for the production and maintenance teams on automation systems, PLC programming, Vision Controls, and troubleshooting techniques.

Key Skills and Qualifications:

• Education: Bachelor’s degree in Electrical Engineering, Control Engineering, Automation, Mechatronics, or a related technical field. Master’s degree or certifications in automation systems is a plus.

• Experience:
• Minimum of 10 years of experience in controls and automation engineering within a Li-Ion Battery Manufacturing or similar high-tech manufacturing environment.
• Proven experience in leading teams and managing large-scale automation projects in manufacturing or process control environments.
• Extensive hands-on experience with PLC, SCADA systems, HMI, IPC, DCS, and other control systems in a manufacturing context.
• Strong background in process automation, integration of control systems with plant equipment, and system troubleshooting.
• Experience with Vision Control Systems for quality inspection, process monitoring, and defect detection, including system setup, integration, and optimization.
• Experience in developing architecture for PLC, HMI, IPC, and communication protocols (e.g., OPC, Modbus, MQTT) to ensure seamless data flow between production equipment and control systems.
• Experience with integrating MES (Manufacturing Execution Systems) and PLM (Product Lifecycle Management) systems into manufacturing control systems to enhance real-time data exchange and optimize production performance.

• Technical Skills:
• Proficiency in programming PLCs, configuring SCADA/HMI systems, and working with various automation hardware and software.
• Experience with control systems design, including power distribution, variable frequency drives, and automation systems for manufacturing processes.
• Familiarity with manufacturing execution systems (MES), ERP, and integration with production lines.
• Experience with Vision Controls and machine vision systems in automated inspection and quality control.
• Strong knowledge of communication protocols (OPC, MQTT, Modbus, etc.) for automation and control system integration.
• Project Management: Proven ability to manage multiple projects simultaneously, including budgeting, scheduling, and resource allocation.
• Analytical and Problem-Solving Skills: Strong analytical skills to troubleshoot control system issues and develop solutions to improve system performance.
• Communication Skills: Excellent verbal and written communication skills, with the ability to interface effectively with cross-functional teams, suppliers, and management.
• Leadership: Experience in managing, mentoring, and developing a team of engineers and technicians in a dynamic, fast-paced manufacturing environment.

Desirable Attributes:

• Experience with advanced automation technologies such as robotics, AGVs (Automated Guided Vehicles), and machine vision systems in manufacturing.
• Knowledge of Lean Manufacturing and continuous improvement methodologies (e.g., Six Sigma, Kaizen).
• A results-driven mindset with a strong focus on operational efficiency and cost optimization.

Working Conditions:

• This position is based in Sanand, Gujarat and may require occasional travel to other company locations, vendors, or suppliers.
• The role will involve working in a manufacturing environment, adhering to strict safety and operational protocols.
• Flexibility may be required to support production schedules and resolve automation system-related challenges promptly.