PLC Technician

The incumbent provides advanced level experience and skillsets in the Technical Department of Otsego Paper LLC. The areas of responsibility include but are not limited to the setup, programming, diagnostics, and troubleshooting of the plant's PLC & DCS control systems - to ensure proper and efficient utilization of equipment, materials and manpower - maximizing safety of personnel and reliability/performance of equipment

Basic Requirements:

· Must be capable of carrying on-call phone and working weekends without assistance.

· Advanced experience with industrial programming, instrumentation, and electrical trades.

· Advanced computer skills (Microsoft office suite, spreadsheets, data entry, etc.)

· Maintain well organized and accurate records relating to equipment maintenance, process efficiency, government agency reports, permits and material requisitions.

· Can read, follow, and modify drawings for large, complex system P&ID’s, system loops, pneumatic/hydraulic schematics, electrical one-lines, mass and energy balances, etc. without assistance.

· Display advanced competencies in the following areas: communication, decision making/problem solving, energy, drive, ambition, job knowledge, leadership, managing conflict/negotiation, managing resources, and work quality.

· Advanced experience with manufacturing instrumentation systems and control panels including adherence to NFPA codes.

· Assist with management of all control systems in the mill:

· Maintenance of all equipment

· RPM Program requirements

· All inspections and SAR requirements

· Electrical Experience – Intermediate Level:

· Wiring diagrams and schematics

· Residential voltage systems (115/230 volt)

· Industrial voltage systems (3 phase 480/2400)

· Switchgear, circuit breakers, fusing

· Motor starters, heaters, pilot circuitry

· Pushbuttons, timers and devices

· VFD setup, operation, maintenance, and troubleshooting

· Instrumentation Experience – Advanced Level:

· VDC and 4-20ma sensors and control devices for pressure, flow, temperature, position, voltage, current, strains, consistency etc.

· Pneumatic control systems (valves/solenoids, positioners, pressures, flows, guides, etc)

· Hydraulic control systems (valves/solenoids, positioners, pressures, flows, guides, etc)

· Steam controls systems (valves/solenoids, positioners, pressures, flows, etc)

· Wiring diagrams and schematics

· Process Control Experience – Advanced Level:

· PLC setup, programming, and troubleshooting for Ladder Logic and Sequential Function Chart environments. Rockwell, Automation Direct.

· DCS/SCADA setup, programming, and troubleshooting in Function Block and Structured Text environments. Foxboro, Ignition.

· HMI setup, programming, and troubleshooting. Rockwell, Ignition, Foxboro.

· Networking of IP devices and understanding of protocols (ethernet IP, TCP/IP, modbus TCP, etc)

· PID Control Loops and Tuning

· Experience with safety systems:

· Integration with legacy systems

· Upgrades to existing

· Basic knowledge of codes

Safety:

· Must be able to perform the essential physical requirements for each position to be considered trained.

· Must know, understand, and follow all applicable model programs plus general plant, department, and job specific safety rules.

· Must be able to protect your own personal safety and the safety of others who may be in your work area.

· Must adhere to applicable responsibilities within the plant’s emergency response program [First-aid, fire, evacuation, etc.)

· Must actively participate in safety program components such as Safety huddles, USG stretching program, BBS, Take 5’s, incident investigations, inspections, and submission of safety improvement ideas.

· Must be able to maintain be proactive to improve good housekeeping practices.

· Must be able to prevent damage to company equipment and materials in areas of assigned responsibility and report damages, incidents, and injuries immediately, when they occur.

· Complete LEAD training as required and all applicable advanced training courses.

· Collaborate with direct supervisors and department leadership as well as Safety Team representatives.

· Must be able to perform this job safely and actively participate in all safety programs. Understand your surroundings and the potential dangers within your work areas.

Continuous Improvement:

Understand the (4) four categories of standard work and identify existing standards when supporting an area.

· Process Adherence

· 5S, Visual Job Aids, Targets & Setpoints, Alignment Markers, Gauge Markers, Job Plans, Out of Compliance Response Plans (Andone Response Plans), Operator Basic Care (OBC’s), and Preventative Maintenance (PM’s)

· Reference

· Bulletin Specifications, Engineering Drawings, and Manufacturing Manuals

· Training

· VWI’s, Job Breakdown Sheets, Training Videos, and Training Plans

· Leader

· Gemba Walks, Coaching, and Reflection Meetings

· Complete 5S LEAD training and support housekeeping initiatives using 5S principles: Sort, Set-in-Order, Shine, Standardize, and Sustain.

Job Procedures and Requirements:

Reporting to the Technical Manager, the incumbent is highly experienced in industrial programming, instrumentation, and electrical trades. They must continually elicit a high standard of safety performance for themselves. The PLC Technician 3 must be proficient in all aspects of the mill control systems and instrumentation.

The incumbent is responsible for assisting with the development and maintenance for the control systems in the mill, power house, and waste treatment. They must possess a high degree of technical aptitude and in-depth knowledge of manufacturing process controls and instrumentation systems. The incumbent must stay abreast of new technologies and work with the engineering group with planning and implementing new capital projects within their area of expertise.

They must demonstrate a solid understanding of mill processes and how the control ystems impact the process. They must be able to access all control systems, troubleshoot, and make programming changes without any oversight. The incumbent is capable of taking high level concepts from their customers and implementing those within their respective area.

They must also be fully proficient and display and advanced level in troubleshooting equipment malfunctions, preventive maintenance work, and routine equipment repairs and overhauls with no oversight.

The incumbent will be a key stakeholder on teams for implementing repair and upgrade projects within their respective department. This includes planning, part specification, coordination, supervision, and successful implementation utilizing both in house and 3rd contractor resources.

Qualifications:

· Licensed Electrician in the State of Michigan preferred.

· 3-5+ Years Industrial Controls and Instrumentation/Electrical Experience.

· USG Safety Model Program, OSHA, FM Global and Environmental compliance experience preferred.

· USG RPM program experience preferred.

· No significant performance/ attendance infractions within the last 6 months.

· Must be able to perform all tasks required in the subsequent positions.

· Must be able to demonstrate assigned job description competency requirements within 12 months of start.

Rate of pay may be adjusted based on the qualifications and experience of the candidate.

USG employees enjoy a number of benefit options for themselves and their families. These include two medical insurance options, as well as vision and dental coverage. The cost of these optional programs varies based on coverage level - employees generally pay 25% of the monthly premium cost, USG pays the rest. These coverage options are offered on the first day of employment with no waiting period.

Additionally, USG employees enjoy both a 401(k) Investment Plan with company match and a pension plan. Beyond these main features, employees may also choose from a number of additional programs like life insurance, accident insurance, legal insurance, even pet insurance, just to name a few. USG also offers Quarterly (hourly) / Annual (salary) bonus potential for all employees based on performance metrics tied to safety, quality, and productivity. USG also provides employees with paid time off and paid holidays.

Since 1902, Chicago-based USG has been a leader in producing innovative, award-winning products and systems to build everything from major commercial developments and residential housing to home improvements. USG's employees are committed to the highest levels of customer satisfaction and quality in everything we do. Our steadfast commitment to the company's core business values – innovation, quality, integrity, service, diversity, efficiency and safety – have helped us become the company we are today.

 EOE including disability/veteran