Controls Programmer

Position: Controls Programmer

Reports to: Controls Programmer Group Leader

General Purpose of Job

To program and develop software for the purpose of controlling specialized automated equipment.

This is a demanding position that requires commitment and continuous learning. Technology is constantly changing and as a Programmer, need to be able to adapt to these changes and embrace new challenges. Efficient, logical thought processes need to be continuously developed to succeed at providing solutions for our customers and the team.

 

Junior Programmer/Developer Duties and Responsibilities

  • Demonstrate an understanding of electrical drawing and proper wiring practices.
  • Participate in wiring of machines and the power up process of machines.
  • Good at troubleshooting problems and using PPE when working around live panels.
  • Be familiar with the following components; PLC, HMI, digital IO, analog IO, machine safety (hardwired, programmed), pneumatic motions

 

PLC/HMI Programming/development at this level will require the following skills;

 

  • Get online with a PLC, HMI and other devices.
  • Understand and modify existing code, write programs based off of existing code standards and structures (PLC and HMI)
  • Configure HMI to interface with PLC.
  • Download HMI and PLC programs.
  • Understand and configure digital IO (NPN, PNP, analog devices, laser sensor)
  • Work with more senior staff to configure typical safety circuits including Estop, light curtains, and gates.
  • Understand Safety Input configuration, safety output configuration, hardware vs software.
  • Program basic code for manual and automatic control of pneumatic actuators.
  • Be aware of VFD documentation and setup procedure.
  • Basic understand of a mechanical dial table, setup of cam switches, indexing vs oscillating.
  • Program and test alarming, messaging, indication specific to process

 

Robot Programming/Development at this level will require the following skills;

 

  • Understand different Robot coordinate systems (joint, world, tool).
  • Able to jog Robots, teach new and touch up existing points.
  • Understand basic instructions (ie. call, jump, wait)
  • Understand robot digital IO and how they are used (ie Wait DI, Set DO)
  • Understand interferences (with robots, fixed tooling)
  • Understand the purpose of and how the Estop circuit functions.
  • Understand how teach and auto work and the difference.
  • Be familiar with existence of offsets.
  • Be aware of the “art” of robot path creation utilizing smooth, efficient motion.

 

Machine Vision Programming/Development at this level will require the following skills;

 

  • Ability to setup hardwired and networked vision sensors for part presence detection.
  • Become familiar with importance of lighting, lenses, filters
  • Setup barcode scanners (1D/2D)

 

Other Duties Include

  • Backup and storage of programs as per Innovative standards.
  • Understand Innovative Automation Inc. scheduling and budget requirements.
  • Communicate effectively with management, fellow staff, and customers the status of current projects, project concerns and possible solutions.
  • Occasional travel as required Globally.

 

 

Intermediate Programmer/Developer Duties and Responsibilities

  • All the skills of a Junior Programmer/Developer
  • Participate in testing and developing PLC/HMI code for new equipment.
  • Custom machinery at this level will include the following components; machine safety (zone enabling and monitoring, spool monitored valves, networked safety to remote devices such as VFDs, robots), servos, label printing, laser markers, machine vision.
  • Basic Database knowledge.
  • Be familiar with the following components; PLC, HMI, digital IO, analog IO, machine safety (hardwired, programmed), pneumatic motion (w/ interferences), VFDs, indexing or oscillating tables, cyclic industrial communications (Ethernet IP, Profinet, Ethercat), robots, machine vision (presence/absence, barcode scanning)

 

PLC/HMI Programming/Development at this level will require the following skills;

 

  • Participate with writing and developing code for new devices and cross platform.
  • Modular code involves the IO mapping for particular function, manual/automatic control, diagnostic and fault handling.
  • Work with more senior staff to configure, program, and participate in validating safety circuits involving robot zoning, hydraulic spool monitored valves, networked safety devices such as robots, servos, VFD’s.
  • Understand and apply safe-torque-off safety wiring and configuration on VFD’s.
  • Configure remote IO with other PLCs, Robots, Etc.
  • Part transfer and status tracking
  • Set up PLC from “Out of the box” State

 

Robots Programming/Development at this level will require the following skills;

 

  • Knowledge of simulation software for verification and programming purposes.
  • Layout Robot structure for IO, job calling, calibrating, recoveries.
  • Setup of tool frames, user frames, payloads
  • Setup and Safety side (i.e. DCS, SafeMove, Cubic-s)
  • Be able to program efficiently using offsets, when needed.
  • Be efficient and smooth with Robot motions and path creation.
  • Work on different types of projects that could include Welding, Material handling, gluing, driving screws, etc.

 

Machine Vision Programming/Development at this level will require the following skills;

  • Experience setting up camera routines in PLC.
  • Able to establish camera and PLC networking.
  • Setup and develop vision inspections such as presence/absence, measurement, part style.
  • Modular part style changeover programming

 

Data Collection Programming/Development at this level will require the following skills;

 

  • Ability to work with more senior staff/IT to specify server requirements for data collection
  • Ability to work with more senior staff/IT to ensure we have appropriate storage capacity and redundancy, clearly communicate as designed/built system capabilities and limitations
  • Ability to work with senior staff to develop solutions for acquiring, storing, querying data from third party devices (ie. Camera inspection images)
  • Ability to query database for results display and validation for running in a station
  • Ability to Interface with existing customer databases and setup SQL to Innovative/customer standard

Senior Programmer/Developer Duties and Responsibilities

 

  • All the skills of a Junior and Intermediate Programmer/Developer
  • Experience testing and developing PLC/HMI code for new equipment such as electric actuators, PLCs, networking
  • Implementing solutions for yearly controls group initiatives (ie. Controls Program/Develop/Install schedule, SQL standardization, machine safety verification procedure)
  • Ability to assist sales during the quote and build phase by reviewing and providing proposals for solutions to our customers process requirements
  • Ability to perform project management throughout the entire phase of the project being worked on.

 

PLC/HMI Programming/Development at this level will require the following skills;

  • Developing project specific PLC/HMI templates for new customer or new platform
  • Program and develop specialized application specific content, ie. LIN communications with customer part, CAN communications with customer part, customer part calibration

 

Robots Programming/Development at this level will require the following skills;

  • Ability to develop project specific robot structure templates for new customer or platform
  • Programming/developing vision for guiding robot

 

Machine Vision Programming/Development at this level will require the following skills;

  • Ability to specify hardware, lighting, lenses, filters for vision inspection for applications such as presence/absence, measurement, part style, 2D/3D profiling, barcode scanning
  • Work with sales to assist with quoting, feasibility, and trials

 

Data Collection Programming/Development at this level will require the following skills;

  • Ability to specify server requirements for data collection
  • Work with customer requirements to ensure we have appropriate storage capacity and redundancy, clearly communicate as designed/built system capabilities and limitations
  • Work with sales to assist with quoting, feasibility, and trials
  • Work with sales, customer, design to ensure overall process is feasible and identify data validity risks (ie. Where in the process does the part receive a unique identifier? Where do we need scanners? Where do we need access to the database?)

 

Relationships

 

  • You will work with Ownership, all department managers, group leaders, and project management pertaining to the status of projects.
  • You will work with Sales, Project Management, Mechanical Design and Controls Design pertaining to scope, concept and engineering of current and probable projects.
  • You will work with electricians and programmers pertaining to the guidance / supervision of project requirements.
  • You will work with Human Resources pertaining to all aspects of the hiring process, discipline, policy development, training requirements etc.

 

Skills and Competencies

 

  • Minimum Diploma in Electrical Engineering or Equivalent Specialized Experience
  • Minimum 2+ Years’ Experience within the Automation or Automotive Manufacturing Field
  • Skills are required to perform multiple, technical tasks with a need to periodically upgrade skills in order to meet changing job conditions
  • Maintain a positive outlook and continuously work on personal development
  • Work cooperatively with others and contribute to a positive workplace
  • Ability to manage tasks and use technology, resources, and time efficiently

 

Occupational Health and Safety Act Responsibilities:

 

Workers have a general duty to protect their own health and safety and that of others around them.  Workers must:

  • Work in compliance to the Act and Regulations
  • Use or wear any equipment, protective devices or clothing required by the employer
  • Not move or make ineffective any protective devices or clothing required by the employer.
  • Report to the employer or supervisor any known hazards or missing or defective equipment or protective devices
  • Report any known violation of the Act or regulations to the employer or supervisor

Workers should be proactive about health and safety.  That means that workers must not only comply with the law, the employer’s policies and workplace procedures, but they should also make suggestions to improve health and safety.  Workers may also bring health and safety concerns and suggestions directly to the Joint Health and Safety Representative (Members names are listed on the Health and Safety Bulletin Board).

 

Physical Demands

This position may require frequent sitting, standing, walking, twisting or rotating. It may require the occasional crouching, squatting, kneeling, bending, climbing and crawling. Working in the electrical department also requires constant cervical flexion, the chin to chest movement. Maximum lifting weight can reach about 75lbs, maximum carrying weight is about 40lbs, and the maximum pushing and pulling weights can reach 100-150lbs. Constant forward reach with both arms as well as constant handling and use of the fingers/pinching are both necessary. This position also requires frequent grasping.

 

Emotional Demands

This position may have external factors that can create the risk of mental fatigue and increased stress.  The person in this position needs to adapt well in the face of workplace stressors such as: working under pressure; working under minimal supervision; understanding and adhering to direction from fellow employees; working with customers to ensure their requirements are met; explaining complex issues to fellow employees, management and customers; working under tight deadlines; competing priorities; ability to adapt to a changing work environment; communicating effectively with fellow employees and customers; travelling globally to customer sites; attention to detail.

Innovative Automation welcomes and encourages applications from people with disabilities. Accommodations are available on request for candidates taking part in all aspects of the selection process.