Sr Automation Controls Engineer

"Unleashing potential, building with certainty."

Position: Sr Automation Controls Engineer

Reporting to: Manager, Project Engineering

Achieve remarkable results with BMI Industrial. No matter the scope, our team confidently navigates complexities to ensure a streamlined and efficient process from contract to completion. With a focus on time and cost savings, serving the Civil, Transportation, Industrial, and Automation sectors, we handle all trades under one roof, providing a cohesive approach that ensures success, cost-effectiveness, and integrated innovation to your(s), and our customer’s needs.

Description of Work ( What You’ll Be Doing ):

BMI Industrial is seeking a highly motivated Automation Controls Engineer to contribute to the design, development, and execution of new automation equipment and mechanical design for a number of key customer projects spanning the Civil, Transportation, Industrial, and Automation sectors.

The Sr Automation Controls Engineer is responsible for development of machine, programming, and process concepts and equipment solutions alongside the Automation Engineering – Mechanical team for small, mid, and large scale industrial automation capabilities. Candidates will be expected to create a robust system architecture to support the concepts of operations for customer-focused projects that range from brand new automation lines and processes; to improving current outdated hardware or process improvements.

Scope of work can range from identifying electrical panel requirements for a project; or utilizing a customer’s pre-existing architecture, then setting up, and programming all controls components such as PLC, safety devices, HMIs, servo drives, process hardware and integrating robots from power-on to debug, and finally to process fine tuning and validation, depending on the project’s needs. In some cases, you will be advising, and troubleshooting pre-existing equipment and processes for a customer to identify process improvement opportunities and recommendations to build both relationships, and continuous improvement work portfolios for future BMI Industrial growth.

The Automation Controls Engineer will also work with cross-functional teams within the Project Engineering group throughout the entire life cycle of the project’s planning, design, implementation, and execution/validation. He/She will be expected to approach all work from a holistic approach to Quality, Safety, Productivity, Improvement and Sustainability to bring components from initial design, through prototype development and finally into full production.

Above all, the Controls Engineer must have a demonstrated excellence in programming PLCs. They must have a well-defined methodology for maintaining code structure and organization. Proven ability to design fault-tolerant systems with error handling and recovery is preferred. Role will require hands-on engagement at BMI’s office, worksites (as required), addressing equipment tools, troubleshooting mechanical, electro-mechanical, electrical and automation controls as needed to implement to project schedule. He/She will work with the Project Engineering leadership and cross-functional team to implement/suggest solutions for machine, project, or customer issues.

This position is customer-facing in some instances, and requires some interacting with contract manufacturers, vendors, or subcontractors for outsourced projects; and working with cross-functional manufacturing, process, quality, and regulatory teams (if applicable) to interface and execute on medium to large-impact equipment launches and programs. Some travel to vendor, customer, or project sites will be required in this role to ensure project execution success. 

This position is part of the Automation Engineering team, reporting to the Project Engineering Manager and will be located at BMII’s HQ in Thorold, ON. Hybrid office options are available for certain candidates.

In this role, you will have the opportunity to:

• Oversee, and own the design and development of automation projects including, initial concept, design requirements, system architecture, test plan, prototype fabrication/testing and commissioning for customer projects.
• Participate in initial customer assessments, equipment conceptual development and carefully balance product specifications, process control requirements, layout complexity, cost, quality and lead-time limits.
• Select, test, and integrate hardware and software components such as robots, analog devices, motion controllers, sensors, vision systems and lasers.
• Generate Robot Simulations to ensure that robot reach, and cycle times can be achieved.
• Architect, write, and debug PLC ladder logic with an emphasis on generating code that is organized, structured, documented, maintainable and reusable. PLC code could interact with subsystems such as conveyors, robots, Manufacturing Execution System (MES), machine vision, and 3rd party equipment per customer specifications.
• Implement (ANSI/RIA15.06/OSHA or MOL-compliant) controls-reliable safety systems for safeguarding robots, gantries, conveyors, and other high volume manufacturing equipment.
• Introduce automated processes into customer environments, and provide accurate documentation for each project with the goal of equipping customers with troubleshooting and training capabilities
• Characterize and validate automated processes using a data driven approach such as simulation, Capacity and Capability statistical test (Gage Repeatability and Reproducibility test, Cpk, etc.) 

At BMI Industrial, our mission is based on delivering seamless solutions with quality, safety, efficiency, and cost-effectiveness in mind; within this, innovation above all drives us to rethink the way our customer’s (and you) do business for our world. 

We look forward to learning about how you can be a part of that mission

Requirements ( What You’ll Bring to Us ):

• Bachelor’s or Master’s Degree in Mechatronics, Automation Engineering Technology, Controls, Electrical Engineering (or related field); or equivalent combination of vocational education and experience at this level
• A minimum of 5+ years of controls, robotics, or systems (electro-mechanical) experience in 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 overall automation system lifecycle from design to implementation and sustainment is preferred
• Thorough knowledge of Safety standards (ANSI/RIA15.06, OSHA) and an advanced-level proficiency in programming industrial equipment safety (i.e. 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 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 Electro-mechanical system design, programming, integration, and sustaining experience; at an engineering-level of hands-on approach
• 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 which involve applications of multi-station parallel processing, pick and place automation, data acquisition, and PID control
• Prior experience in 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; with assigned target deadlines, qualification requirements and deliverables (documentation, metrics, and design reviews);
• Knowledge of, or experience in basic shop tool use, drilling, tapping; or 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 industry-competitive compensation plan (Salary + Performance Reward), BMI Industrial offers a fully comprehensive, and inclusive benefits and vacation (PTO) program for you and your family from Day One.

In addition, due to the nature of our work, employees within this role are eligible for stipends under our various Taxable Benefits Policy . This includes, but is not limited to:

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