Job Description
About the Role
We are establishing a new dairy manufacturing facility in Hugoton, Kansas, producing processed milk, creamers, and cream cheeses across process, utilities, filling, and packaging operations. This is a greenfield opportunity to build the site's automation function from the ground up.
As the Senior Automation Engineer, you will be one of two automation professionals responsible for the entire automation and controls landscape at the site. You will own everything from PLC programming to server infrastructure, from day-to-day fault resolution to automation capital project delivery. This is a deeply hands-on role. You will be programming, troubleshooting, and maintaining systems yourself every day, while also providing technical leadership, steering projects, and coordinating with suppliers and global teams.
Key Responsibilities Hands-On Automation and Control Systems
- Program, configure, troubleshoot, and maintain PLC, HMI, and SCADA systems on the Rockwell Automation platform (ControlLogix, CompactLogix, FactoryTalk View).
- Own the full Rockwell Automation portfolio at the site: firmware management, licensing, patching, and platform health.
- Develop and optimize control logic for pasteurization, separation, homogenization, batching, filling, CIP/SIP systems, and utility systems.
- Manage and maintain virtualization infrastructure (Hyper-V, VMware ESXi) and Windows Server environments that host automation applications.
- Configure, troubleshoot, and maintain industrial network infrastructure including Ethernet/IP, and TCP/IP protocols.
- Manage system backups, version control (Rockwell AssetCentre), and technical documentation for all automation assets.
Maintenance of Automation Assets
- Take ownership of the preventive maintenance program for all automation and control system assets, including PLCs, HMI terminals, SCADA servers, network switches, and virtualization hosts.
- Perform corrective maintenance and fault resolution to minimize production downtime.
- Maintain a spare parts strategy for critical automation components.
- Track and manage automation asset lifecycle, including firmware versions, hardware revisions, and end-of-life planning.
Project Leadership
- Lead automation-related capital and improvement projects from concept through commissioning and handover.
- Develop technical specifications, functional descriptions, and system architecture documentation.
- Coordinate with equipment OEMs, system integrators, and vendors to ensure system compatibility and performance.
- Manage project timelines, budgets, and deliverables for automation scope.
- Conduct and oversee Factory Acceptance Testing (FAT) and Site Acceptance Testing (SAT).
Manufacturing Support
- Provide real-time, hands-on troubleshooting support to operations and maintenance teams during production.
- Analyze equipment performance data to identify root causes of downtime or process variation.
- Lead and participate in root cause analyses (RCA) and Management of Change (MOC) processes.
- Support commissioning, startup, and validation of new equipment and process lines.
- Ensure all automation changes follow plant change-control procedures.
Compliance and Safety
- Ensure control systems meet regulatory and industry standards (FDA, PMO, OSHA, NFPA, 3-A Sanitary Standards).
- Maintain and improve safety interlocks, alarms, and emergency-stop systems.
- Support quality and food safety initiatives, including traceability, batch control, and audit readiness.
Continuous Improvement and Collaboration
- Identify opportunities to automate manual processes and improve plant efficiency.
- Support digital transformation initiatives including data historians, MES, and predictive maintenance.
- Train and mentor plant personnel, including the junior automation engineer, on systems, controls, and best practices.
- Collaborate with global engineering and global IT teams on standards alignment, knowledge sharing, and cross-site initiatives.
Qualifications Required
- Tertiary qualification in Electrical Engineering, Automation, Mechatronics, Control Systems, or a related technical discipline.
- Minimum 5 years of hands-on experience in automation or controls engineering within food, beverage, dairy, or process manufacturing.
- Strong proficiency in PLC and HMI programming on the Rockwell Automation platform.
- Proven ability to independently manage the full Rockwell ecosystem including firmware, licensing, patching, and AssetCentre.
- Solid understanding of industrial networking protocols including Ethernet/IP and TCP/IP.
- Hands-on experience with server virtualization platforms (Hyper-V and/or VMware ESXi) and Windows Server administration.
- Experience with instrumentation, VFDs, servo systems, and process control loops.
- Ability to read electrical schematics, P&IDs, and control system documentation.
- Demonstrated experience leading automation projects and coordinating with external suppliers and integrators.
- Understanding of dairy processing operations and sanitary manufacturing requirements.
Preferred
- Experience with Ignition SCADA platform (Inductive Automation).
- Experience with Sepasoft MES modules (Track & Trace).
- Familiarity with Wonderware/AVEVA Historian or similar process data historians.
- Knowledge of pasteurization controls, CIP/SIP automation, and PMO requirements.
- Experience working with global or multi-site engineering teams.
Core Competencies
- Self-starter who thrives in a greenfield environment with minimal oversight.
- Strong analytical and troubleshooting skills with a hands-on mentality.
- Project leadership and stakeholder management.
- Excellent communication and cross-functional collaboration.
- Attention to detail and commitment to food safety.
- Ability to balance daily operational demands with longer-term project delivery.
- Continuous improvement mindset.
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