Middelburg: Process, Control and Development Engineer (PC & D Engineer) posted by Aleon Pty Ltd

Job Description:

Our client is seeking a Process Control & Development Automation Engineer to join their Process Control & Development department at the Hot Rolling Mill to be part of a team that is the custodian of the highly automated slab re-heating and hot rolling Level 2 modelling and some of the Level 1 control systems. The team maintains and improves these higher level recipe (Level 2) systems and some of the technology intensive lower level (Level 1) automated process control systems. These systems include First Principal feed forward models and feedback control loops as well as Artificial Intelligence systems in the form of Fuzzy Logic Expert Systems and Neural Networks to ensure continuous process performance improvement.

The ideal PC&D Engineer has a passion to automate processes and to improve process control to tight specifications, believing in the value of performance improvement through better automation. At the highly automated Hot Mill these automation upgrades will be based on world best practices in steel heating and rolling theory and principles. The engineer will study currently used modelling and control logic and do prioritize software upgrades based on literature studies, own in-plant research, or as guided by PC&D management or other subject experts in the team. The PC&D Engineer will own the outcomes of the softwares effects on the product and process performance and will zealously improve these systems – based on prioritized value-add needs.

Additionally, the PC&D Engineer also plans, directs and co-ordinates hot rolling process improvements to affect quality, efficiency and availability and maintains close control on critical product characteristics. The PC&D Engineer implements corrective and preventive actions to assure quality and effective process performance. The engineer is responsible for investigating and assisting to reduce equipment failure in the incumbents field of expertise.

Responsibilities:

The incumbent will provide a service to the Business Unit in order to minimize delay times and enable the plant to perform at its maximum effectiveness at all times. It can be expected to investigate and solve problems as they occur.

Services to the business unit include:

• Identify problem areas requiring improvement as directed by business KPIs.
• Quantify the underlying contributory causes to the problems.
• Study the problem at the hand of the contributory causes and propose solutions.
• Implement solutions including automation, mistake proofing, manufacturing procedures etc.
• Sustain and continuously improve performance through the automated systems and processes.
• Plan, direct and co-ordinate hot rolling process improvements linked to PC&D systems to improve quality, efficiency and availability.
• Investigate all modelling and control system failures and associated deviations to implement corrective and preventive actions.
• Implement solutions to assist with process and product development in association with Level 1 or 2, Technical and Production departments through consultation with other disciplines/departments.

Maintain and develop the following systems:

• Heat transfer modelling (finite element heat transfer Level 2 model) and combustion systems (Level 1).
• Rolling modelling (Level 2): Speed, temperature, forces, torques and flatness control models (including neural network).
• Level 1 thickness, flatness, strip cooling and coiling mostly feedback control systems.
• Expert System for continuous process parameter optimization of the heating and rolling processes (including Fuzzy Logic).

• Weekly standby on a rotational basis with the other PC&D team members.
• Ensure compliance with the goals as defined in KPI’s.
• Identify problems, investigate solutions and solve problem in order to achieve those goals.
• Constantly co-ordinate process deviations with all relevant parties.
• React and correct all substandard process conditions.

Qualifications:

• Eng (Electrical, Electronic, Metallurgical or Mechanical) or Computer Science, Computer Engineering, or related field.

Skills and Experience:

• Experience in Software development (C, C++, C#, Visual Basic, etc.), specifically in the engineering control software field.
• Knowledge of Level 2 type first principal models for heating and rolling technology.
• Knowledge of how these Level 2 models is automatically calibrated using artificial intelligence or other simpler methods.
• Knowledge of control systems and instrumentation is a plus.
• Creative and strong problem-solving and analytical skills.
• Experience working in a manufacturing or industrial environment is a plus.
• Enjoys working in the field of engineering solution development.