Senior Process Control Engineer
Greater Augusta, Georgia Area| Full-Time | Confidential Search
This is a senior-level role for an automation professional ready to serve as the site's technical authority on process control - leading complex projects, mentoring junior engineers, and driving continuous improvement in a GMP manufacturing environment.
Why This Opportunity:
- Growth -The company is scaling quickly, creating real opportunities for personal and professional advancement for motivated, results-oriented engineers.
- Ownership - You'll be given the resources and freedom to succeed, with a culture of high expectations and mutual accountability.
- Mission - Join a team that loves what it does and is passionate about working on the cutting edge of sustainable manufacturing.
What You'll Do:
Technical Leadership & Advanced Engineering
- Serve as site SME for process control systems - PLC, DCS, HMI, SCADA, and associated instrumentation - providing authoritative guidance to engineering and operations teams.
- Lead the design, configuration, testing, and commissioning of complex control systems for new and modified processes, ensuring integration with upstream and downstream operations.
- Evaluate and select control hardware and software platforms; develop and enforce site-wide standards for control architecture, programming conventions, and documentation.
- Lead advanced troubleshooting of process control issues; perform root cause analysis (RCA) and drive implementation of permanent corrective and preventive actions (CAPA).
Project Management & Capital Support
- Own and lead area capital projects from scope development and cost justification through control logic design, factory acceptance testing (FAT), and site commissioning.
- Develop project plans, manage timelines, coordinate contractor and vendor activities, and communicate project status to engineering and site leadership.
- Review and approve engineering deliverables including P&IDs, control narratives, cause-and-effect matrices, functional specifications, and as-built documentation.
- Mentor and guide junior process controls engineers on project execution and technical best practices.
Production Support & Continuous Improvement
- Provide senior-level technical support to Production for control system configuration, process control parameter changes, and troubleshooting across multiple systems.
- Partner with Production and Process Development to identify and implement improvements in automation, efficiency, data collection, and reporting.
- Champion continuous improvement initiatives that reduce downtime, improve process reliability, and increase overall equipment effectiveness (OEE).
- Analyze process and historian data to identify control performance gaps and recommend enhancements to control strategies.
Training, Documentation & Compliance
- Develop, maintain, and deliver training programs for console operators on automated systems, including training materials and process simulation tools.
- Ensure all control system work and documentation adheres to site GMP guidelines, change control procedures, and applicable regulatory standards.
- Support site safety and quality initiatives through active participation and leadership in incident investigations, CAR analysis, and follow-up actions.
- Maintain accurate, complete documentation in accordance with good documentation practices (GDP) and site quality management systems.
What We're Looking For:
- Bachelor's degree in Engineering (Chemical, Electrical, Mechanical, or related discipline)
- 5–7+ years of progressive experience in process controls or automation engineering in a manufacturing environment; biotech, pharmaceutical, or specialty chemical experience strongly preferred
- 5–7+ years of progressive project management experience
- Demonstrated hands-on expertise with PLC and/or DCS platforms (e.g., Rockwell, Siemens, Emerson DeltaV, Honeywell) including programming, configuration, and commissioning
- Proven experience leading capital projects, including scope development, cost estimation, and site commissioning
- Strong knowledge of process instrumentation (flow, pressure, temperature, level, analytical) and control loop tuning
- Solid understanding of safety, health, environmental, quality systems, and GMP regulatory compliance requirements
- Excellent verbal and written communication skills, with the ability to present technical content to technical and non-technical audiences
- Strong analytical and problem-solving skills; demonstrated ability to lead RCA investigations and implement lasting solutions
- Physical ability to perform equipment inspection and troubleshooting in a manufacturing environment, including climbing stairs and ladders and wearing required PPE
- Work schedule flexibility during shutdowns and other extraordinary operational conditions
Nice to Have:
- Experience with bioprocess automation, fermentation systems, or bio-facility environments
- Proficiency with SCADA systems, historian platforms (e.g., OSIsoft PI), and MES integration
- Familiarity with ISA-88 batch control standards and ISA-99/IEC 62443 industrial cybersecurity standards
- Knowledge of 21 CFR Part 11 requirements for electronic records and signatures in a GMP setting
- Experience with process simulation tools and operator training systems (OTS)
- Professional Engineer (PE) license, or actively pursuing one
- Prior experience mentoring or leading junior engineering staff
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