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Senior Automation Control Specialist

2 months ago


Thorold, Ontario, Canada BMI Industrial Full time

"Empowering innovation, constructing with assurance."

Position: Senior Automation Control Specialist

Reporting to: Project Engineering Manager

Achieve exceptional outcomes with BMI Industrial. Regardless of the project scale, our team adeptly manages complexities to guarantee a smooth and effective process from initiation to completion. With an emphasis on time efficiency and cost-effectiveness, we serve the Civil, Transportation, Industrial, and Automation sectors, managing all trades under one roof to provide a unified approach that ensures success, cost savings, and integrated innovation tailored to our clients' needs.

Job Responsibilities (What You Will Be Engaged In):

BMI Industrial is on the lookout for a driven Automation Control Specialist to play a pivotal role in the design, development, and implementation of new automation systems and mechanical designs for several key customer projects across the Civil, Transportation, Industrial, and Automation sectors.

The Senior Automation Control Specialist will be tasked with the development of machinery, programming, and process concepts, collaborating with the Automation Engineering – Mechanical team on projects of varying scales. Candidates are expected to devise a comprehensive system architecture to support operational concepts for client-focused projects, ranging from entirely new automation lines and processes to enhancing existing outdated systems.

Responsibilities may include determining electrical panel specifications for a project or leveraging a client's existing architecture, setting up and programming all control components such as PLCs, safety devices, HMIs, servo drives, and process hardware, as well as integrating robotic systems from initial power-on through debugging and process fine-tuning, depending on project requirements. In certain instances, you will provide guidance and troubleshoot existing equipment and processes to identify opportunities for improvement, fostering relationships and continuous improvement initiatives for future growth at BMI Industrial.

The Automation Control Specialist will also collaborate with cross-functional teams within the Project Engineering group throughout the entire project lifecycle, from planning and design to implementation and validation. A holistic approach to Quality, Safety, Productivity, Improvement, and Sustainability will be essential in bringing components from initial design through prototype development to full production.

Above all, the Controls Specialist must demonstrate excellence in PLC programming, possessing a well-defined methodology for maintaining code structure and organization. A proven ability to design fault-tolerant systems with effective error handling and recovery is preferred. This role will require hands-on involvement at BMI's office and worksites, addressing equipment tools, troubleshooting mechanical, electro-mechanical, electrical, and automation controls as necessary to adhere to project timelines. You will work closely with Project Engineering leadership and cross-functional teams to implement and propose solutions for machine, project, or client challenges.

This position may involve direct interaction with clients and requires collaboration with contract manufacturers, vendors, or subcontractors for outsourced projects, as well as working with cross-functional manufacturing, process, quality, and regulatory teams (if applicable) to interface and execute medium to large-scale equipment launches and programs. Some travel to vendor, client, or project sites may be necessary to ensure successful project execution.

This role is part of the Automation Engineering team, reporting to the Project Engineering Manager and will be based at BMI Industrial's headquarters. Hybrid office options may be available for suitable candidates.

In this role, you will have the opportunity to:

  • Lead and manage the design and development of automation projects, including initial concepts, design specifications, system architecture, testing plans, prototype fabrication/testing, and commissioning for client projects.
  • Engage in initial client assessments, equipment conceptual development, and carefully balance product specifications, process control requirements, layout complexity, cost, quality, and lead-time constraints.
  • Select, test, and integrate hardware and software components such as robots, analog devices, motion controllers, sensors, vision systems, and lasers.
  • Create Robot Simulations to ensure robot reach and cycle times are achievable.
  • Architect, write, and debug PLC ladder logic, focusing on generating organized, structured, documented, maintainable, and reusable code. PLC code may interact with subsystems such as conveyors, robots, Manufacturing Execution Systems (MES), machine vision, and third-party equipment per client specifications.
  • Implement safety systems compliant with ANSI/RIA15.06/OSHA or MOL standards for safeguarding robots, gantries, conveyors, and other high-volume manufacturing equipment.
  • Introduce automated processes into client environments and provide comprehensive documentation for each project, equipping clients with troubleshooting and training capabilities.
  • Characterize and validate automated processes using a data-driven approach, including simulation and statistical tests (e.g., Gage Repeatability and Reproducibility tests, Cpk, etc.).

At BMI Industrial, our mission revolves around delivering seamless solutions with quality, safety, efficiency, and cost-effectiveness at the forefront; within this framework, innovation drives us to rethink how our clients conduct business in our world.

We look forward to discovering how you can contribute to this mission.

Qualifications (What You Will Bring to Us):

  • Bachelor's or Master's Degree in Mechatronics, Automation Engineering Technology, Controls, Electrical Engineering (or a related field); or an equivalent combination of vocational education and experience at this level.
  • A minimum of 5+ years of experience in controls, robotics, or systems (electro-mechanical) within any relevant regulated industry such as Automotive, Civil/Construction, Aerospace, Medical Device, or similar.
  • Experience with high-speed assembly automation tools, precision mechanisms, tooling, GD&T, machine tolerances, industrial robotics (Fanuc, ABB, Kuka, or Mitsubishi), and the overall automation system lifecycle from design to implementation and maintenance is preferred.
  • Thorough knowledge of safety standards (ANSI/RIA15.06, OSHA) and advanced proficiency in programming industrial equipment safety (e.g., Safety PLCs such as Allen Bradley & Siemens).
  • Some experience in Human-Machine Interface (HMI/GUI) programming for SCADA or assembly tooling (Allen Bradley, Siemens, Ignition).
  • Experience with Field Bus Networks (Ethernet IP, ProfiNet, Safety-Rated Field Bus Networks, etc.).
  • Basic proficiency in, or certification with various 3D Design Packages (Solidworks, Edgecam, Vizendo, Inventor, Pro E, AutoCAD, DELMIA Apriso, CATIA, ANSYS) or the ability to interpret CAD models and schematics.

It would be a PLUS if you also possess previous experience in, or have a:

  • Professional Engineering License (P.Eng), Certified Engineering Technologist (CET), or equivalent.
  • 8+ years of hands-on experience in electro-mechanical system design, programming, integration, and maintenance at an engineering level.
  • Proficiency in major PLC languages within a high-volume manufacturing system design role (Rockwell, AB, Siemens Step 7/TIA, Beckhoff, Mitsubishi, or similar).
  • Ability to program state machines for complex processes involving multi-station parallel processing, pick and place automation, data acquisition, and PID control.
  • Prior experience with high-volume SCARA or industrial robotics (Epson, Fanuc, Kuka, Mitsubishi, Omron).
  • Hands-on experience with electro-mechanical troubleshooting, qualification, integration, and debugging in an automated manufacturing environment, adhering to assigned deadlines, qualification requirements, and deliverables (documentation, metrics, and design reviews).
  • Knowledge of or experience in basic shop tool use, drilling, tapping, welding, fabrication, turning, CNC, etc.
  • Experience in ISO13485 or a similar Quality-Regulated measurement system/organization and/or working knowledge of data analysis, statistics, SPC, and quality-improvement methodologies.

Benefits:

In addition to our competitive compensation package (Salary + Performance Reward), BMI Industrial offers a comprehensive and inclusive benefits and vacation (PTO) program for you and your family from Day One.

Furthermore, due to the nature of our work, employees in this role are eligible for stipends under our various Taxable Benefits Policy, which includes, but is not limited to:

  • 4 Weeks Paid Vacation
  • RRSP Matching Program
  • Mileage (as prescribed by the Canadian Revenue Agency rates)
  • Per Diems (for travel and workdays requiring hotel stays)
  • Living Out Allowance (in company-owned properties)
  • Lodging