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Process Control Engineer Resume Samples
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0-5 years of experience
Provided technical support, trained operators, wrote SOPs for ISO 9000 compliance. Implemented standard work instructions, utilized SPC and root-cause analysis tools.
- Achieved 50% product measurement reduction with statistical sampling methods
- Reduced product start-up scrap resulting in 1% savings per Ribbon manufactured
- Implemented a nondestructive measurement technique that eliminated a costly non-value added testing method resulting in a 3% yield increase
- Increased inking line speed by 50% with a $1000 investment eliminating the need to order more equipment ~ $150K in cost avoidance to increase capacity
0-5 years of experience
Supervised forty union electricians. Directed long-term engineering and planning activities.
- Managed systems planning, designed metering, substation maintenance and provided technical consultation for plant processes.
- Coordinated the installation of new PLC systems designed software; performed testing, implementation and maintenance activities for major aspects of projects assigned.
- Managed the upgrade of controlling equipment installation and start-up, this $600,000 project increased reliability by 85%.
- Designed, developed, constructed and installed voltage monitoring equipment for six substations well under budget.
- Produced OSHA compliant work plans complete with OSHA prescribed standards and specifications for all areas in violation.
- Established Standard Operating Procedures; produced Severstal's first set of company-wide procedures for instruments or none-standard equipment associated with the ISO 1400 standards.
0-5 years of experience
Responsible for department production quality, MRP & ERP, process control and coordinating production flow thru national and international divisions. Delegate responsibilities for improvements in product quality and production process control
- Implemented product quality awareness thru VSOP's, for continuous improvement and improved product quality.
- Identify, analyze and resolve technical process and operational issues.
- Designed MRP compatible database system to monitor process control and product quality defects. Generate various reports to define quality metrics and identify procedures/processes requiring improvement (LEAN).
- Developed Production system to influence on time product delivery and improved customer metrics by 30%
- Initiated Time studies to improve inefficient processes and gained ~17% improvements in production capacity.
0-5 years of experience
Maintained process planning and SPC projects.
- Developed a quality plan that contributed 9% improvement in the end of line audit scores and 2 % improvement in yield by incorporating quality work elements into the assembly work instructions.
- Reduced potential service calls by 25 % by improving the braze process and potential leaks.
- Developed training plan, which addressed temporary labor performance issues and enabled the department to meet quality and production requirements during peak production periods.
- Identified supplier problems and was active in the problem solving process which assisted the suppliers in maintaining specifications.
- Set up SPC for Critical to Quality parts in fabrication area.
10+ years of experience
Reduced process alarms by 65%.
- Improved regulatory loop performance by 40%.
- Tracked and reported process control metrics and identified and implemented improvements.
- Troubleshoot and repair process control equipment programs and hardware.
- Improved process operations cost and reliability through improving existing PLC and DCS programs and through implementing new PLC and DCS programs.
- Managed process control systems planning, purchases, installation, commissioning and start-up on capital and expense projects.
- Trained process operators and electrical and instrumentation technicians on both regulatory and supervisory controls.
6-10 years of experience
Installed new equipment, analyzed and developed solutions to reduce breakdowns in existing equipment, including PLC programming to ensure maximum operation of hot strip rolling mill.
- Interfaced with production and manufacturers' engineers on various small to large new installation and upgrade projects
- Selected to travel to Japan to conduct acceptance testing; installed, tested, and ensured interface
- Led a team (identified project requirements and criteria to create and manage program schedules) in the analysis of QC in each area which resulted in the reduction of out of tolerance work 50%+.
- Successfully completed hot strip mill automation upgrade project from manual to automated controls with Toshiba DCS equipment
- Maintained and modified SCADA based Intellution HMI system
- Alpha/VMS, Toshiba PLCs, GE DMC, GE PLCs, Rockwell-AB PLCs; Intellution and Rockwell HMI Controls; network communication, web applications, and more
0-5 years of experience
Developed and implemented process improvements to reduce costs to the amount of over $4 Million.
- Coordinated with the Human Resources department, and served as the recruiter for new campus engineering recruits.
- Managed the $250 Million upgrade for Logic controls on various Sheeters which lead to a 65% Return on Investment.
- Served on the Mill re-design team which helped increase overall mill efficiency by over 20% and saved the company over $2 Million.
- Assisted with project planning sessions to determine final scope, task lists, risk and mitigation strategies, communication plan, etc.
- Assisted with the development of alternative systems to meet company set goals and requirements.
- Supervised and assisted with numerous mill and capital projects ranging in budgets from $50 thousand to $1 Million.
- Collected and analyzed measurements generated from the Quality Control and Web Inspection Systems for paper quality assurance.
- Assumed the fill-in supervisor role for operators and contractors during the absence of lead managers.
6-10 years of experience
Maintained two Honeywell Measurex Quality Control Systems, and two ABB Camera Systems. Maintained two ABB Quality Control Systems.
- Maintained Fisher Provox DCS. Tuned and optimized loops.
- Worked with E/I to maintain and optimize Foxboro and Yokogawa controllers.
- Helped convert these positions from a supplier role to internal owner role
- Substantially reduced cost of service while improving service.
- Significantly improved availability and accuracy of systems.
- Maintain IT equipment (PC's, switches, and printers).
6-10 years of experience
- Designed Kaizen for quality events reduced paint defects by 30%
- Assigned as Quality Assurance Engineer to largest customer and reduced PPM by 40%
- Engaged production employees by involving them on monthly visits to customer
- Achieved a Certified Welding Inspector certification
- Trained new hires
0-5 years of experience
Designed, coordinated and installed capital projects with budgets ranging from $20K to $200K to support site manufacturing and R&D operations. Managed and supervised the daily activities of hourly employees in batching and applying process coating slurries and solutions.
- Project Manager / Team Leader for new capital and process improvement projects including; I-P clarifier, UF and RO process waste water treatment system upgrade with pre-filter system, acid fume exhaust system, laboratory dust collection system.
- Evaluated a high speed batching mixer manufactured and used in JM South Africa.
- Served on a team responsible for commissioning and start-up of a new auto catalyst plant in Belgium.
- Identified costly problem with disposal of spent precious metal solutions and created a corrective action plan that saved over $100K annually.
0-5 years of experience
Developed new control strategy for two large industrial natural gas heaters for improved safety and operability, and successfully restarted the heaters on schedule
- Led process control effort for design, installation, and start-up of industrial heaters with hydrogen as a second fuel source for two large industrial heaters. Annual cost savings estimated at greater than $1 million per year. Efforts included coordination with contractors, vendors, and various functional groups.
- Process control resource for multiple areas of a large chemical facility with various chemical processes and different control systems (Moore/Siemens, Honeywell)
- Assisting in design of control system for $100 million chemical plant to be built in Spain
- Responsible for programming, testing, and start-up of control system for new plant
- Implemented a Six Sigma project to identify and reduce nuisance alarming in multiple production areas across the plant
- Mentored two summer interns and one new employee in process control group
0-5 years of experience
Provided engineering and maintenance support for instrumentation and process control systems for international chemical company.
- Trained, supported, and mentored personnel installing, operating and maintaining the instrumentation and process control systems.
- Designed, implemented, troubleshooted, and documented logic configurations for PLC and DCS systems (ABB-Bailey DCS - Infi-90, Composer, and Conductor-NT).
- Maintain current instrumentation and process control documentation including specifications.
- Worked with project and process engineers to develop, start up, and document new processes.
- Coordinated contractors' work of installing process control instrumentation.
0-5 years of experience
- Improved First Time Dyeing (FTD) efficiency from 65% to 80% by increasing precision and accuracy of the methods.
- Managed introduction of Datacolor International Datamatch color recipe formulation system to replace the current obsolete color formulation system.
- Trained color lab personnel in the use of Datamatch color recipe formulation system, automated solution makers, infrared lab dyeing machines, and various hand-held devices (pH and conductivity meters, and Rainin digital pipettes).
- Performed spreadsheet calculations using Microsoft Excel for tracking performance of dye house production figures.
0-5 years of experience
Developed, implemented and monitored process control standards in the Slabbing Mill Department.
- Provided departmental training in the use of statistical process control techniques.
- Functioned as departmental project engineer and liaison to vendors.
- Formed and was team leader of labor-management participation team involved in cooperative problem solving.
- Identified and implemented new concept in soaking pit covers targeted at $1MM annual savings.
0-5 years of experience
Developed all validation activities for electro-mechanical devices (diagnostics & ventilation)
- Responsible for all IQ, ES, OQ, and PQ activities for new facility as well as diagnostics and ventilation groups.
- Developed project plans for a facility validation effort - Initalizing, Planning, Maintaining & Control, Execution, and Close.
- Wrote and performed several different validation activities for the following projects - eDHR project, Facilities Validation activities (Project Plan, Work Breakdown Structure, Risk Analysis, etc)
- Updated and improved statistical sampling procedures.
- Coached, mentored others on validation techniques as well as Six Sigma Green Belt techniques.
- Lead validation team in CAPA activities.
0-5 years of experience
- Assisted in the As-Is P&ID walkdown for the TCACP project and modified diagrams as necessary.
- Modified FCCU1's FORTRAN programming for catalyst circulation with temperature and pressure correction in the FOX 1/A.
- Modified control scheme for FCCU1's E-6 Gasoline Splitter for improved reliability and level control.
- Updated and provided DCS displays and alarming for environmental limits in FCCU1 and FCCU3.
- Provided troubleshooting and technical support on a daily basis for the Cracking Division.
0-5 years of experience
- Supervised and direct a line crew of 4 - 6 union operators.
- Ensured state-of-the-art robotic precision coater lines are operating within specifications.
- Reduced cost by regulating precision precious metal application and keeping waste to a minimum.
- Oversaw production from start to finish, controlled quarantine and ensured in spec product are shipped.
- Assisted with new technology transfer from Analysis, Development and Implementation to Production.
- Monitored the overall process status using Wonder ware, a PLC base program (HMI)
Process Control Engineer Duties and Responsibilities
The type of organization a process control engineer works for will determine the exact duties they carry out day to day. Based on job listings we analyzed, a process control engineer's duties typically involve:
Analyzing Processes Process control engineers analyze how processes affect the overall production and final product, and find ways that these systems can be improved and developed to be more effective.
Performing Troubleshooting Tasks Process control engineers troubleshoot plant equipment and systems to identify areas for improvement and to spot any faults which are limiting the efficiency of the equipment or processes.
Project Planning Project planning is an important part of a process control engineer's job. This involves leading project management of upgrades throughout the plant and working with colleagues to find the best solution to projects.
Implementing Improvements Process control engineers implement process improvements to increase the efficiency and costs of processes. They create and implement new strategies to improve productivity for the company, as well as support start-up activities.
Determining Costs Process control engineers work out the costs of labor, equipment, and materials required for any suggested process improvements.
Process Control Engineer Skills and Qualifications
Process control engineers should have strong math and analytical skills, as well as troubleshooting abilities and teamworking skills. Typically, employers will require a bachelor's degree in engineering and previous experience in a similar role, as well as the following abilities:- Analytical skills - process control engineers effectively analyze data sets to draw conclusions and make the right evaluations of procedures, so strong analytical skills are important to this job
- Math skills - process control engineers use math principles to troubleshoot design and analysis areas in their work
- Problem-solving abilities - in designing processes, process control engineers need to identify problems before or as they occur, such as safety issues and problems related to the manufacturing
- Interpersonal skills - process control engineers need to develop good relationships with their colleagues to work successfully on projects and developing production processes
- Detail oriented - process control engineers must have great attention detail in order to spot inaccuracies and faults, and find solutions to them.
Process Control Engineer Education and Training
The minimum requirement to become a process control engineer is a bachelor's degree in engineering, or a similarly technical field, as well as several years' experience in a relevant role. Employers will typically expect to see evidence of extensive production and manufacturing knowledge to perform this role well. Process control engineers may also gain a degree in the industry they want to work in, such as chemical engineering, electrical engineering, or computer science. Leadership experience and skills are often advantageous in this job, as process control engineers are often required to carry out leadership tasks as well.
Process Control Engineer Salary and Outlook
The median annual salary for process control engineers is nearly $71,000, according to PayScale. Process control engineers in the 10th percentile earn around $54,000 annually, while the highest paid earn close to $98,000 a year. Some companies offer packages that can reach up to $10,000 from bonus structures based on individual or group performances, and up to $29,000 in commission opportunities. Most employers offer dental plans and medical insurance as part of their benefits package. The Bureau of Labor Statistics predicts that the growth rate for chemical engineers is expected to grow by eight percent through 2026.
Helpful Resources
We've collected some of the best resources to help you develop your career as a process control engineer.
Automation and Control Engineering - a group with more than 119,000 members, this LinkedIn group was designed for professionals to share information and insights, and give their opinions on the topic of automation and processes. For process control engineers who are new to the industry, this is a great way to find out about new developments in technology and learn about new job opportunities.
"4 Big Benefits of Process Control Instrumentation" - this blog post covers four reasons why process control is so valuable in businesses, and why it's important to develop a cohesive understanding of goals to work towards.
Process Control Engineering - this book covers the main topics of process control, with illustrative examples and easy-to-comprehend information that will help readers understanding how process control systems can be integrated into other disciplines to help develop more effective processes.
Process Control: Modeling, Design and Simulation - this book provides a complete introduction to process control, which helps readers master the key techniques using MATLAB-based computer simulations. It provides a foundation on how to design systems and processes which will help create more efficiency and productivity in the plant.
Quality Control Cover Letter Examples
