Senior Engineer, PLC Automation

Full Time

Holland, MI, US

LG Energy Solution Michigan Inc. (LGESMI) develops and manufactures large lithium-ion polymer batteries and packs for electric vehicle (EV) and energy storage applications. Come join the leader in advanced EV batteries!

Summary:

The Senior Engineer, PLC Automation is an ESMI-based controls engineer responsible for providing specialized automation and technical support to LG Energy Solution and affiliated manufacturing entities throughout North America.

This position supports the development, deployment, commissioning, startup, stabilization, troubleshooting, and optimization of PLC-based control systems used in lithium-ion battery electrode mixing processes. The Engineer serves as a technical expert in LG Energy Solution electrode mixing control programs, PLC and HMI systems, recipe management, alarm management, NMP process control, automated material handling, and manufacturing-system communications.

The Engineer travels to North American manufacturing sites to support new-line launches and production ramp-ups, resolve complex control-system and process-automation issues, implement control-logic improvements, and transfer specialized knowledge to locally hired controls engineers and maintenance personnel.

Responsibilities:

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  Provide advanced PLC, HMI, and automation engineering support to ESMI and other LG Energy Solution or affiliated North American manufacturing entities.

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  Support the deployment, configuration, commissioning, startup, and optimization of control programs used in lithium-ion battery electrode mixing systems.

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  Develop, modify, test, and troubleshoot PLC programs using Siemens, Mitsubishi, LS, and Omron control platforms.

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  Develop and optimize HMI screens, equipment interfaces, operator controls, process-monitoring functions, and production-status displays.

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  Develop, modify, and validate recipe-management functions supporting different battery products, materials, process conditions, and production requirements.

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  Develop and optimize process-control logic for electrode mixing systems, including NMP piping pressure control, material transfer, automated cleaning, and related process sequences.

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  Develop, modify, and troubleshoot automated Pig system programs used for material transfer, piping recovery, cleaning, and process-efficiency improvement.

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  Develop and commission communication interfaces between electrode mixing equipment and Automated Guided Vehicles or other automated material-handling systems.

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  Manage alarm lists, interlock logic, fault conditions, equipment status signals, and process-monitoring functions.

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  Diagnose and resolve complex PLC, HMI, network communication, instrumentation, control-sequence, equipment-interface, and process-automation issues.

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  Support line acceptance testing, equipment commissioning, trial production, production ramp-up, and mass-production stabilization.

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  Analyze recurring equipment faults, process interruptions, communication failures, and control-system performance issues; conduct root-cause analysis and implement corrective actions.

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  Modify control programs and operating sequences to improve process stability, equipment reliability, cycle time, production efficiency, and product quality.

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  Develop production-reporting, work-log management, and equipment-performance applications supporting manufacturing operations.

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  Review and update electrical drawings, control-panel drawings, I/O lists, network architectures, equipment specifications, and control-system documentation.

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  Coordinate technical activities with process engineering, manufacturing, maintenance, IT, equipment suppliers, contractors, and engineering teams across multiple entities and locations.

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  Maintain controlled records of PLC and HMI software versions, program changes, parameter modifications, testing results, alarms, and corrective actions.

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  Train locally hired controls engineers, technicians, operators, and maintenance personnel on PLC architecture, HMI operation, recipe management, alarm response, equipment communications, and troubleshooting procedures.

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  Provide on-site technical support during new plant launches, major control-system failures, production interruptions, and other critical manufacturing events.

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  Travel frequently to manufacturing facilities throughout North America based on project and operational requirements.

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Required Skills:

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  Advanced PLC programming and troubleshooting skills using Siemens, Mitsubishi, LS, or Omron control platforms.

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  Specialized knowledge of PLC-based control systems used in lithium-ion battery electrode mixing or comparable chemical-processing and material-handling operations.

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  Strong HMI design, programming, modification, and troubleshooting capabilities.

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  Experience developing and managing automated recipe-management systems for manufacturing processes.

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  Experience designing alarm-management systems, equipment interlocks, fault-handling logic, and process-monitoring functions.

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  Knowledge of electrode mixing process sequences, material flow, piping pressure control, and related process automation.

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  Experience developing or modifying NMP process-control logic and automated piping or material-recovery sequences.

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  Experience integrating PLC-controlled equipment with AGVs or other automated material-handling systems.

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  Ability to diagnose PLC, HMI, industrial network, I/O, sensor, actuator, motor, inverter, and equipment-interface issues.

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  Experience with equipment commissioning, line acceptance testing, production startup, ramp-up, and stabilization.

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  Ability to read and update electrical schematics, control drawings, I/O lists, network diagrams, and equipment technical specifications.

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  Working proficiency with AutoCAD Electrical or comparable electrical-design software.

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  Strong root-cause analysis, change-control, technical documentation, and production-support skills.

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  Ability to transfer specialized control-system knowledge to local engineers, technicians, operators, and maintenance personnel.

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  Ability to work effectively across multiple manufacturing sites, corporate entities, cultures, and technical functions.

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Qualifications:

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  Bachelor’s degree in computer science, electrical engineering, controls engineering, automation engineering, mechatronics, or a related field required. An associate degree in a related discipline combined with substantial directly relevant PLC and automation experience may be considered.

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  At least 4 years of progressively responsible experience in PLC programming, industrial automation, manufacturing control systems, or related equipment-engineering functions.

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  Demonstrated experience developing, commissioning, and troubleshooting PLC and HMI systems used in automated manufacturing environments.

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  Demonstrated experience with at least two major PLC platforms, such as Siemens, Mitsubishi, LS, or Omron.

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  Experience supporting lithium-ion battery manufacturing, electrode mixing, chemical-process equipment, or comparable automated process-manufacturing systems.

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  Experience with equipment startup, commissioning, acceptance testing, production ramp-up, and mass-production troubleshooting.

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  Experience supporting manufacturing projects at multiple facilities or international locations.

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  Ability to communicate effectively in English in technical and operational settings.

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  Ability and willingness to travel frequently throughout North America.

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  Ability to work flexible or extended hours during commissioning, production ramp-up, control-system failures, emergency troubleshooting, and other critical project periods.

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Benefits Overview:

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  100% employer-paid Medical, Dental, and Vision premiums for you and your family

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  100% employer-paid disability and life insurance

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  Generous Paid Time Off / Holidays

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  Opportunity to grow in a diverse work environment with a global company

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  401k Retirement savings and planning with a generous company match

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LGESMI is an Equal Opportunity employer that values the diversity of its workforce.