Location: Atlanta, GA(Day One Onsite)
Exp: – 8 to 10 Years
Job Summary / Objective:
Expert Controls Engineer for a long-term engagement to provide advanced support for Beckhoff Twin CAT PLC systems operating in a 24/7 medically regulated, cGMP-compliant facility.
The role involves investigating, developing, testing, and optimizing PLC programs, enhancing EtherCAT diagnostics, integrating and validating safety systems, and conducting specification monitoring defeat analyses. The position demands a high standard of technical documentation, regulatory compliance, and cross-functional collaboration to ensure system reliability and product quality.
Key Responsibilities:
1. PLC & Control System Development
- Investigate, design, develop, and validate PLC code using Beckhoff TwinCAT and EtherCAT platforms.
- Support program enhancements, troubleshooting, and performance optimization for continuous manufacturing processes.
- Apply best practices in version control, code documentation, and change management.
2. Diagnostics & Monitoring
- Develop and improve EtherCAT hardware diagnostics, HMI messaging, and fault logging systems.
- Identify, document, and mitigate potential monitoring or alarm bypasses.
- Conduct and document root cause investigations for specification or signal deviations.
3. Safety Systems Integration
- Enhance, validate, and document PLC-based safety logic and interlocks.
- Verify compliance with applicable safety and regulatory standards (e.g., ISO 13849, IEC 62061).
- Collaborate with site safety and validation teams to ensure proper testing, approval, and release.
4. Regulatory & Quality Compliance
- Ensure all design and testing activities align with cGMP, FDA, and quality system requirements.
- Maintain traceable documentation suitable for a regulated environment (design history, test records, change logs).
5. Specification Monitoring:
- Investigate and report on potential monitoring bypasses; develop mitigations, test mitigations to reduce OOS manufacture of goods.
Key Deliverables:
- Approved and version-controlled TwinCAT PLC code with supporting documentation.
- Investigation and validation reports with recommendations and mitigations.
- Comprehensive test plans and execution reports.
- Updated and compliant system documentation.
- Periodic status reports and final summary report.
Qualifications & Experience:
Requirement
Description
Education
Bachelor’s degree (B.E. / B.Tech.) in Electrical, Electronics, Mechatronics, or Controls Engineering.
Experience
8+ years in controls engineering, with at least 4 years in Beckhoff TwinCAT and EtherCAT environments. Should have experience on complex automation line.
Regulatory Experience
Prior work in medically regulated or cGMP manufacturing facilities is essential.
Technical Skills
Beckhoff TwinCAT, EtherCAT network configuration, PLC safety systems, and industrial communication protocols. May also need Siemens experience for specific module optimization. 1 to 2 years of experience in B & R
Soft Skills
Strong analytical and problem-solving ability, excellent documentation and communication skills, and a collaborative mindset.
Thanks & Regards
Mohammad Faisal
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