Senior PLC Programmer (3-4+ years Experience)

Experience :

• 3 to 4+ Years

Educational Qualification :

• Diploma / BE / B.Tech in -
• Electrical Engineering
• Electronics & Instrumentation
• Mechatronics
• Automation Engineering
• Related Field

Reports To:

Manager

Job Purpose

To develop, test, commission, and maintain PLC-based automation programs for Special Purpose Machines (SPMs), conveyors, assembly systems, and industrial automation projects as per customer requirements, ensuring quality, safety, and timely project completion.

Key Responsibilities

1. Requirement Analysis

• Understand customer applications, process requirements, and project scope.
• Participate in customer meetings and site visits for technical discussions.
• Collect and analyze inputs required for program development.

2. Flow Chart Development

• Prepare machine operation flowcharts and sequence diagrams.
• Create presentations (PPT) explaining machine logic and operation.
• Submit flowcharts to customers for approval.
• Modify flowcharts based on customer feedback and requirements.

3. PLC Programming

• Develop PLC programs according to approved machine sequences.
• Configure PLC hardware and communication systems.
• Validate all Inputs and Outputs (I/O) through PLC controllers before implementation.
• Upload and test programs on machines.

4. HMI Development

• Design customer-specific HMI screens.
• Create operation pages, setting pages, alarm pages, and maintenance pages.
• Implement password-protected access levels as per customer requirements.

5. Manual Mode Verification

• Verify individual machine operations in manual mode.
• Check ON/OFF functionality of:
• Motors
• Solenoid Valves
• Pneumatic Cylinders
• Sensors
• Light Curtains
• Reed Switches
• Safety Interlocks
• Validate all Inputs and Outputs (I/O).

6. Auto Mode Verification

• Verify machine operation in automatic sequence mode.
• Ensure all interlocks function correctly.
• Validate operation based on:
• Light Curtain Status
• Part Present Sensors
• Reed Switch Sensors
• Safety Conditions
• Verify machine cycle completion as per approved sequence.
• Implement running status and alarm/error messages.

7. Internal Testing & Validation

• Conduct complete in-house machine trials.
• Participate in customer witness trials.
• Rectify programming issues identified during testing.
• Update software based on customer feedback.

8. Documentation & Audit

• Perform self-audit of program sequences.
• Verify software compliance with approved customer requirements.
• Maintain programming records and revision history.
• Prepare backup copies of final PLC and HMI programs.
• Support preparation of operation manuals and technical documentation.

9. Installation & Commissioning

• Support machine installation at customer sites.
• Conduct commissioning and production trials.
• Troubleshoot PLC, HMI, sensor, and communication issues.
• Obtain customer approval after successful machine operation.

10. Program Backup & Maintenance

• Create and maintain final software backups.
• Ensure latest approved software versions are securely stored.
• Support future modifications and service requirements.

Required Skills

Technical Skills

• PLC Programming (Mitsubishi, Omron, Siemens, Delta, Allen Bradley, etc.)
• HMI Development
• Industrial Automation Systems
• Sensor Integration
• Pneumatic and Electrical Control Systems
• Industrial Communication Protocols
• Machine Sequence Logic Development
• Troubleshooting and Commissioning
• Should have panel wiring knowledge

Software Knowledge

• GX Works
• CX Programmer
• TIA Portal
• WPLSoft / ISPSoft
• HMI Configuration Software
• Microsoft Office

Key Performance Indicators (KPIs)

1. Program completion as per project schedule.
2. First-time-right machine trials.
3. Number of programming errors during customer trials.
4. Commissioning success rate.
5. Customer approval without major rework.
6. Documentation and backup compliance.
7. Project delivery adherence.
8. Machine uptime during trial runs.

Authority

• Recommend software modifications for machine performance improvement.
• Approve program backups before project closure.
• Coordinate with Design, Electrical, and Production departments for project execution.