Senior Specialist, Manufacturing Automation

Job Description
Position Summary:
The Senior Specialist, Manufacturing Automation provides technical leadership and automation support for capital projects and manufacturing operations at the Dallas, Texas, facility. The position supports the startup, commissioning, qualification, operation, maintenance, and continuous improvement of manufacturing automation and mechanical systems.
The position reports to the Engineering Manager and works closely with the Associate Director of Operations, Maintenance, Operations, Quality, Information Technology, equipment suppliers, and other cross-functional partners. The role operates as an individual contributor with responsibility for technical leadership, project execution, contractor oversight, and cross-functional coordination.
Specific Responsibilities:
Automation Strategy and System Reliability:
Evaluates automation and information technology systems and develops strategies to improve system reliability, quality, maintainability, and long-term performance through expansion, replacement, or upgrade.
Apply technical expertise to ensure the safe, reliable, and efficient operation of automated processing equipment and supporting information technology systems.
Identifies and implements automation, process, and equipment improvements that increase manufacturing efficiency, reliability, and operational performance.
Develops technical requirements that consider operational needs, system capabilities, lifecycle costs, business benefits, compliance requirements, and implementation risks.
Serves as a liaison among site teams, corporate automation groups, divisional automation teams, and Information Technology.
Controls Engineering and Technical Support:
Develops programmable logic controller (PLC) and human-machine interface (HMI) code for new equipment and supports existing control systems.
Configures and commissions variable-frequency drives (VFDs).
Configures subnet addressing and industrial network communications.
Provides on-floor technical support for manufacturing operations.
Troubleshoots complex automation, controls, equipment, and system issues and develops sustainable corrective actions.
Participates in investigations of automation anomalies, determines contributing factors, and implements actions to prevent recurrence.
Analyzes system performance, operating data, and equipment trends to identify emerging issues and improvement opportunities.
Capital Projects and Project Execution:
Coordinates project activities across Engineering, Operations, Quality, Information Technology, procurement, equipment suppliers, contractors, and other stakeholders to achieve approved scope, schedule, cost, and compliance objectives.
Provides technical leadership for equipment installation, startup, commissioning, qualification, and transfer into routine operations.
Leads project coordination, troubleshooting, implementation, and change-control activities.
Plans, attends, and executes vendor Factory Acceptance Testing and Site Acceptance Testing.
Oversees contractors and consultants to ensure project deliverables meet agreed-upon technical, quality, schedule, and customer requirements.
Initiates and leads collaboration among Operations, Quality, Engineering, and technical teams to resolve complex technical and operational problems.
Technical Documentation and Qualification:
Works with internal customers and stakeholders to define equipment and process requirements.
Develops User Requirements Specifications (URS), Functional Requirements Specifications (FRS), and Detailed Design Specifications (DDS) for automation and equipment projects.
Reviews and approves technical specifications and design documents prepared by equipment suppliers, consultants, and other external providers.
Supports the planning and execution of commissioning and qualification activities.
Develops and updates standard operating procedures and other technical documentation required to support project implementation and routine operations.
Develop Job Safety Assessments as required.
Supports internal and external audits by preparing technical information, responding to automation-related observations, and implementing corrective actions.
Training and Operational Readiness:
Develops and delivers training for operators, technicians, engineers, and other users of automated systems.
Supports operational readiness by ensuring that systems, documentation, training, and technical support are in place before equipment is released for routine use.
Participates in technical training programs and maintains current knowledge of relevant automation technologies, standards, and industry practices.
General Requirements:
Key Competencies:
Build effective working relationships with employees, business partners, customers, contractors, and leaders at all organizational levels.
Collaborates effectively across Engineering, Operations, Quality, Information Technology, procurement, and other functional teams.
Demonstrates technical leadership and influences outcomes without relying solely on formal authority.
Applies a structured, analytical approach to troubleshooting, problem-solving, risk assessment, and decision-making.
Communicates complex technical information clearly to both technical and nontechnical audiences.
Manages changing priorities and multiple assignments while maintaining attention to quality, safety, schedule, and compliance.
Works independently, exercises sound judgment and takes appropriate action when facing obstacles or ambiguity.
Demonstrate flexibility and the willingness to work outside standard business hours when required to support projects or manufacturing operations.
Physical Requirements and Work Environment:
Ability to use handheld measuring and diagnostic devices.
Ability to sit, stand, and walk for extended periods during the workday.
Ability to lift and carry up to 50 pounds on an occasional basis.
Ability to climb stairs and ladders to access equipment and system components.
Ability to work at a computer for extended periods.
Ability to work periodically in non-climate-controlled spaces.
Ability to access manufacturing and equipment areas while following all applicable safety and personal protective equipment requirements.
Qualifications:
Minimum Education Requirements:
Bachelor’s degree in Engineering, Science, Information Technology, or a related technical discipline.
Required Experience and Technical Skills:
A minimum of seven years of relevant experience in process automation, manufacturing automation, controls engineering, or a related field.
Experience developing, modifying, troubleshooting, and supporting PLC- and HMI-based control systems.
Experience supporting equipment installation, startup, commissioning, qualification, or validation activities.
Ability to interpret and develop technical specifications, system requirements, design documents, and operating procedures.
Demonstrated ability to troubleshoot complex automation, equipment, and manufacturing-system issues.
Strong written and verbal communication skills.
Demonstrated technical leadership and experience leading project teams, contractors, consultants, or cross-functional workgroups.
Strong time-management and organizational skills, including the ability to manage changing workloads and complete assignments independently.
Demonstrated analytical, problem-solving, and decision-making skills, including the ability to act appropriately when faced with obstacles or ambiguity.
Preferred Qualifications:
Experience in a regulated manufacturing environment.
Experience developing or reviewing User Requirements Specifications, Functional Requirements Specifications, and Detailed Design Specifications.
Experience with industrial networks, variable-frequency drives, data acquisition, system administration, and automation-system integration.
Experience overseeing equipment suppliers, contractors, or automation consultants.
Experience training operators, technicians, engineers, or other users of automated systems.
Travel and Work Schedule Requirements:
Ability to travel up to 30%.
Ability to work flexible hours when necessary to support project execution, equipment startup, manufacturing operations, or urgent technical issues.
Required Skills:
Automation, Automation Technology, Capital Project Management, Control Systems Engineering, HMI Programming, Manufacturing Operations, Operations Support, PLC Programming, Technical Leadership, Technical Training
Preferred Skills:
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