Key Responsibilities and Required Skills for Manufacturing Systems Engineer

🎯 Role Definition

We are seeking a hands-on Manufacturing Systems Engineer who will design, implement, and optimize manufacturing control systems and digital infrastructure to maximize throughput, quality, and uptime. This role combines systems engineering, automation, MES/SCADA integration, and continuous improvement methods (Lean, Six Sigma) to enable reliable, scalable, and data-driven production operations across multiple lines and facilities. The ideal candidate will have experience with PLC/HMI programming, MES/ERP integration, IIoT sensor architectures, and a proven track record of delivering complex automation and system modernization projects on-time and on-budget.

📈 Career Progression

Typical Career Path

Entry Point From:

Manufacturing Engineer (Process/Production)
Controls or Automation Technician/Engineer
Industrial Engineer with automation exposure

Advancement To:

Senior Manufacturing Systems Engineer / Lead Systems Engineer
Automation or Controls Manager
Plant Engineering Manager / Director of Manufacturing Engineering

Lateral Moves:

Process Engineer (with focus on automation/process control)
Controls Systems Architect / PLC Lead
Quality Engineering (automation-driven quality systems)

Core Responsibilities

Primary Functions

Lead the end-to-end design, development, and deployment of Manufacturing Execution Systems (MES), including process workflows, data models, transaction logic, and integrations with ERP systems to ensure real-time production visibility and traceability.
Architect and implement PLC and HMI control strategies for new and existing production equipment, including ladder logic/structured text programming, firmware management, and version control to ensure deterministic, safe machine behavior.
Plan, manage, and execute automation and system modernization projects (PLC/SCADA/MES upgrades), producing detailed project plans, risk assessments, budgets, and vendor scopes-of-work while coordinating cross-functional stakeholders to deliver on schedule.
Drive MES-to-ERP integration and data exchange designs (e.g., OEE, production orders, inventory movements, quality events) using APIs, database replication, OPC UA, or middleware technologies to eliminate manual data entry and improve data integrity.
Lead commissioning, start-up, and validation activities (IQ/OQ/PQ as applicable) for automation systems and production lines, authoring test protocols, acceptance criteria, and performing hands-on system and performance testing with production stakeholders.
Design and maintain SCADA and industrial historian architectures that capture time-series data, alarm/event logs, and key process variables, enabling analytics, dashboards, and predictive maintenance models to reduce downtime.
Troubleshoot and resolve complex production control, integration, and communications issues (PLC/RTU/HMI/SCADA/MES), performing root cause analysis (RCA) and implementing corrective actions to improve mean time between failures (MTBF).
Specify, evaluate, and manage relationships with automation vendors, system integrators, and subcontractors, overseeing technical scope, deliverables, FAT/SAT processes, and warranty issues to ensure alignment with design requirements.
Develop and deploy IIoT sensor strategies and edge computing solutions to collect high-resolution process and asset health data, including sensor selection, network design, and secure telemetry to cloud or on-prem analytics platforms.
Drive continuous improvement and process optimization initiatives using Lean, Kaizen, and Six Sigma methodologies to improve throughput, reduce cycle time, and improve first-pass yield through control-system enhancements and data-driven interventions.
Author technical design documents, control narratives, electrical and I/O lists, network diagrams, and system architecture diagrams to provide clear implementation and maintenance guidance to engineering and operations teams.
Implement industrial cybersecurity controls for OT environments, including network segmentation, secure remote access practices, patch management coordination, and enforcement of IEC 62443/ISA 99 principles to protect production systems.
Create and maintain standardized control libraries, reusable PLC/HMI templates, and MES process modules to accelerate future automation projects, reduce variation, and ensure consistent engineering practices across plants.
Collaborate with process engineering, quality, and production operations to translate manufacturing requirements into system specifications, acceptance tests, and training materials to ensure new systems meet operational needs.
Develop production KPIs (OEE, cycle time, downtime codes, scrap rates) and build real-time dashboards and alerts that enable plant leadership to make faster, data-driven decisions and escalate issues proactively.
Lead diagnostics and corrective actions for complex electrical/control failures on production equipment, coordinating electrical, mechanical, and controls teams to restore production with minimal impact to schedule.
Plan and execute upgrades of legacy control systems and instrumentation, ensuring backward compatibility, data migration, and minimal process disruption while modernizing platforms for scalability and maintainability.
Mentor and train operators, maintenance technicians, and junior engineers on control system operation, safe work practices, and use of MES/SCADA interfaces to improve adoption and reduce operational errors.
Implement automated test benches and simulation models for PLC/HMI/MES logic to validate control strategies and accelerate FAT processes, reducing commissioning time on the plant floor.
Lead root cause investigations for recurring process deviations or equipment failures using structured problem-solving approaches (5 Whys, Fishbone, DMAIC) and drive closure of corrective actions with measurable impact.
Drive standard operating procedures (SOPs) and change control processes for software releases, PLC logic changes, and MES configuration updates to minimize unplanned outages and ensure traceability of changes.
Collaborate with data science and IT teams to enable predictive analytics and digital twin initiatives by ensuring high-quality, contextualized manufacturing data flows and metadata tagging are implemented at the system level.

Secondary Functions

Support cross-functional continuous improvement workshops and Kaizen events by providing systems-level input and implementing automation-related recommendations.
Contribute to asset lifecycle planning by providing input on spare parts, firmware versioning, and obsolescence mitigation strategies for control hardware and instrumentation.
Provide ad-hoc data extracts, diagnostic logs, and event histories to support production investigations and compliance audits.
Assist in budget forecasting for controls and automation projects, providing technical estimates and vendor quotes to support capital planning.
Stay current with Industry 4.0 trends, IIoT platforms, and best practices, recommending pilot projects that align with business priorities and ROI criteria.
Participate in plant safety reviews and risk assessments related to control systems, interlocks, and safety instrumented systems (SIS).
Coordinate with corporate IT on network design, time synchronization, and directory/service accounts to ensure secure and reliable OT/IT integration.
Support regulatory compliance activities (ISO, FDA cGMP, CE, UL) as they relate to manufacturing systems, providing documentation and evidence for audits.

Required Skills & Competencies

Hard Skills (Technical)

Manufacturing Execution Systems (MES) implementation and configuration (examples: Siemens Opcenter, Rockwell FactoryTalk, Wonderware MES, Apriso).
PLC programming and troubleshooting (Allen-Bradley/Rockwell, Siemens S7, Schneider, or equivalent) and structured text / ladder logic proficiency.
SCADA and HMI design and administration (Wonderware/AVEVA, Rockwell FactoryTalk, Ignition) and alarm management best practices.
OPC UA/DA, MQTT, RESTful APIs, and other industrial communication protocols for system integration and data exchange.
ERP integration experience (SAP, Oracle, Microsoft Dynamics) including BAPI/IDoc, web services, or middleware/ESB knowledge.
Industrial networking fundamentals (Ethernet/IP, Profinet, Modbus/TCP), VLANs, and OT network segmentation.
Data collection, historian configuration (OSIsoft PI or similar), and data modeling for analytics and OEE calculation.
IIoT/edge computing platforms and sensor integration (edge gateways, time-series ingestion, local preprocessing).
Test-driven commissioning skills: FAT/SAT/IQ/OQ/PQ protocol development, test execution, and remediation tracking.
Industrial cybersecurity awareness and familiarity with IEC 62443 / NIST CSF principles for OT.
CAD/engineering drawing comprehension and ability to create control wiring diagrams, I/O lists, and panel layouts.
Programming/scripting for automation tasks and data transformation (Python, SQL, or similar for ETL and analytics support).
Experience with Lean manufacturing, Six Sigma, DMAIC problem solving, and continuous improvement project leadership.
Cloud/on-prem architecture knowledge for manufacturing data platforms and experience collaborating with data engineers or cloud architects.

Soft Skills

Excellent cross-functional communication skills with the ability to translate technical requirements into business value for operations and leadership.
Strong problem-solving and analytical mindset, able to lead structured root cause investigations and implement corrective actions.
Project management and prioritization skills; comfortable managing multiple concurrent automation projects and vendors.
Collaborative team player who can mentor junior engineers and upskill operations/maintenance staff.
Adaptable and pragmatic decision-maker under production pressure, with a focus on safety, quality, and uptime.
Attention to detail and discipline around documentation, change control, and version tracking for critical systems.
Stakeholder management and negotiation skills when working with external system integrators and procurement teams.
Continuous learning orientation and curiosity about digital manufacturing trends and new automation technologies.
Customer-focused mindset: prioritizes solutions that improve operator experience and reduce human error.
Results-driven with a bias for measurable outcomes (reduced downtime, increased OEE, reduced cycle variability).

Education & Experience

Educational Background

Minimum Education:

Bachelor's degree in Electrical Engineering, Mechanical Engineering, Industrial Engineering, Mechatronics, Controls, Systems Engineering, or related technical discipline.

Preferred Education:

Master’s degree in Systems Engineering, Automation, Controls, or an MBA with a technical background; certifications in controls, MES, or Six Sigma (Green/Black Belt) are a plus.

Relevant Fields of Study:

Electrical Engineering
Mechanical Engineering
Industrial/Manufacturing Engineering
Mechatronics / Controls Engineering
Systems Engineering / Automation

Experience Requirements

Typical Experience Range:

3 to 8 years in manufacturing automation, controls engineering, MES implementation, or systems integration roles.

Preferred:

5+ years of progressive experience implementing MES and PLC/SCADA systems in discrete or process manufacturing, with demonstrated ownership of at least two full lifecycle automation projects (requirements -> deployment -> commissioning -> continuous improvement).
Prior exposure to ERP integration, industrial networking, OT cybersecurity, and IIoT initiatives.
Practical experience working on-site in production environments and coordinating cross-functional teams (operations, quality, maintenance, IT).