Description

Tuwaiq Casting & Forging is seeking a skilled and technically advanced Automation Engineer to join the Maintenance Department. Reporting to the Maintenance Manager, this role works at a professional level handling the engineering review, design, and analysis of control systems and information technologies across the entire facility. The Automation Engineer serves as the subject matter expert for melting, casting, forging, heat treatment, machining, and utilities automation systems, and is responsible for implementing best practices, strategies, and methods to increase overall equipment effectiveness.

Key Responsibilities

Environment, Health & Safety (EHS)

Adhere to EHS regulations and guidelines and maintain a safe working environment at all times
Follow EHSS safety standards, prepare Risk Assessments (RA) and Job Safety Analyses (JSA), and maintain safe performance of all work
Maintain safety interlocks, alarms, and emergency shutdown systems, and ensure automation systems comply with applicable safety standards and regulations
Contribute to reporting near misses and incidents, and participate in HAZOP studies, site inspections, audits, and investigations
Maintain the workplace clean and tidy at all times in line with company standards.

Engineering & Maintenance Support

Support the alignment, implementation, and technical delivery of the operational reliability level specified for the facility
Assist the maintenance department in implementing the site-wide maintenance strategy, incorporating lessons learned
Provide advanced troubleshooting capabilities to resolve complex technical problems and restore systems and equipment to operational condition
Serve as the focal point for plant automation systems including PLCs, HMIs, SCADA, and VFDs, and maintain programme and parameter backups for all such systems
Assist with maintenance, emergency repairs, and inspections, and provide technical automation support to maintenance supervisors and technicians as assigned
Diagnose and troubleshoot hardware and software faults; minimise downtime by responding promptly to plant and equipment failures to maintain high availability and reliability of control systems and their networks
Optimise control logics to improve plant efficiency and identify opportunities for automation improvements
Provide recommendations for preventive, predictive, and corrective maintenance for facility automation systems, and monitor and administer the execution of preventive maintenance plans
Participate in site inspections and safety, quality, or production investigations as assigned
Collect and analyse engineering data, evaluate conceptual engineering plans, and prepare and assess designs and plans in accordance with specifications
Conduct Bad Actor and chronic Failure Elimination and Root Cause Analysis (RCA) studies as required, and follow up on the implementation of recommendations with concerned parties
Review and ensure technical proposals for outsourced automation maintenance services include a clear scope of work; oversee automation maintenance services
Ensure that data, drawings, and documentation received from project contractors and vendors are complete and in accordance with contract specifications
Review and assist in reliability methodologies including RCM, RBI, and RIS; assign equipment criticality rankings, perform failure analysis, and recommend mitigation strategies
Work closely with area engineers, maintenance supervisors, and planners to ensure each automation system has a maintenance plan and that required spare parts are ordered and stocked
Attend supplier automation integration tests, participate in factory acceptance tests, and support site-based commissioning of automation equipment and systems
Propose revamping and CAPEX projects, prepare scopes of work and specifications to improve facility and equipment availability, and participate in reviewing, supervising, and implementing approved projects
Follow Management of Change (MOC) procedures for all system or programme modifications, and record maintenance activities and system changes
Implement 5S, Total Productive Maintenance (TPM), Lean Manufacturing (LM), and Reliability Excellence (REX) for automation across the facility.

HR, Leadership, Training & Coaching

Provide on-site, hands-on mentorship to newly hired automation and electrical engineers and technicians, including training, coaching, and guidance on work control and maintenance processes
Assist with the recruitment of experienced and competent engineers, maintenance supervisors, and technicians
Prepare and deliver training courses on automation systems to maintenance team members to improve skills across operations, engineering, and maintenance functions
Develop and maintain effective and positive relationships with a wide range of personnel.

Reports Generation

Support the establishment and implementation of maintenance work control and performance monitoring procedures and KPIs
Ensure maintenance schedules are accurately maintained and that maintenance reports are correctly entered into ERP Asset Management and communicated to all relevant focal points in a timely manner
Develop technical maintenance and engineering reports as requested.

Requirements

Education

Bachelor's degree in Electrical or Control Systems Engineering with a minimum of 7 years of technical experience in a similar field.

Technical Competencies

Working knowledge of engineering principles and practices in melting, casting, forging, and machining facilities, or relevant industry in automation and instrumentation
Specialised training in instrumentation and automation
Experience with MES, DCS, HMI, Automated Storage, PLC, Advanced Process Control (APC), Emergency Shutdown Systems (ESD), Machine Monitoring, and instrumentation devices
Strong knowledge of PLCs including Siemens 400 and 1500 Series Safety PLCs, LS PLCs, and SCADA
Strong knowledge of VFDs from manufacturers including Siemens, ABB, LS, Delta, Danfoss, and Hisolution
Proficiency in TIA Programming and SCADA for Siemens PLCs, HMIs, and VFDs
Proficiency in FANUC and Siemens Controllers programming for CNC machines
Proficiency in Simatic Manager programming for Siemens redundant PLCs
Familiarity with IBA system for problem analysis
Strong knowledge of automation networks including Profinet, Profibus, Modbus, and Ethernet TCP/IP
Strong understanding of electrical and control schematics
Data gathering techniques for organising and interpreting data, with the ability to compile, interpret, and apply field notes, data tables, and other information to engineering problems
Computer literacy including ERP Asset Management and MS Office software.

Behavioral Competencies

Strong problem-solving and analytical skills
Ability to communicate effectively in English, both orally and in writing
Ability to read, understand, and interpret complex technical information and documentation
Ability to establish and maintain effective working relationships
Ability to present research findings in clear, objective written report form.