Process Control Engineer II/Lead

Metallus • Canton, OH • 1d ago

Joining the Metallus team means becoming part of a legacy that dates back over a century. We are an industry leader, manufacturing the cleanest steel in the world for companies in the industrial, aerospace and defense, automotive, and energy markets. Purpose A Process Control Engineer or PCE is responsible for improving and maintaining the steel manufacturing automation systems. This position can work and/or be located at any of the three Canton steel plants, the Harrison Steel Pant - HSP, the Faircrest Steel Plant - FSP or the Gambrinus Steel Plant - GSP. Manufacturing control systems are divided into Level 1 and Level 2 components. PCEs at Metallus are involved in both the Level 1 and the Level 2 components. Level 1 devices are input/output devices (switches, gages, valves, motors, etc.) These Level 1 devices are connected to Level 1 Programmable Logic Controllers or PLCs. The PLCs and their applications read the Level 1 inputs, and act on the Level 1 outputs. The PLCs are high-speed, low-level controllers designed for both safety and reliability. The Level 2 components at Metallus generally include Windows Application servers, SQL database servers, and Windows terminal servers. The floor level workstations used by operators and maintainers are generally robust Thin Clients that connect to the afore-mentioned servers. Most Process Control Servers have been virtualized. These Virtual Machines or VMs are hosted on Metallus server clusters for added security and reliability. All the manufacturing control systems are custom built for our manufacturing processes. They are designed and built in accordance with our equipment vendor specifications and with our Metallus PCE specifications. Responsibilities PCEs implement changes to the process control systems in a controlled, safe, well-reasoned, responsible, and timely manner. PCEs maintain and prioritize their work in coordination with their manager and the departments that they are working in. PCEs plan and work to keep PLCs, Windows Systems, Software, and all controls modern, patched, and secure.

PCEs may implement Level 1 hardware or PLC changes. They make design and modification changes to smart devices including drives, vision systems, gauges, and other smart sensors. PLCs are programmed using ladder logic, function block diagrams, and standard text languages. PCEs are expected with training to debug and make PLC program changes.

The process control engineer helps ensure all Level 1 system changes are well documented. PCEs make sure drawings and program changes are updated and commented properly. They also work with electrical maintainers, and process control technicians to verify that they maintain and document changes correctly as well.

Custom Level 2 applications are typically written using Microsoft .NET, C#, C++, or Visual Basic. Most systems also have SQL databases. PCEs are expected with training to debug, maintain, and create functional, and reliable Level 2 applications.

Some of the automation systems make use of Human Machine Interface or HMI applications. These include Ignition, Factory Talk, IFix, and WinCC. PCEs use these software tools to create and modify operator screens in these areas.

PCEs build and maintain interfaces to other Steel Business computer systems. These systems provide data to and need data from the manufacturing control systems. These systems include scheduling, data reporting, and historical recording systems. PCEs may be called upon to provide reports and other data at the request of others. This is especially true when PCEs are working with others during capital and improvement projects.

PCEs verify Level 1 and Level 2 systems are backed up and that disaster recovery procedures are in place.

Many Metallus areas operate 24 hours per day, and some operate 7 days per week. Responsible PCEs ensure systems run during all ho

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