Process control engineers are responsible for the design, implementation, and oversight of a variety of software-driven automation systems. The job can vary greatly depending on the setting; some of these professionals work in factories with complex machines, while others work in labs overseeing pharmaceutical production or in the aerospace industry maintaining the integrity of space and aircraft maintenance, to name a few options. The core elements of the job, however, are nearly always the same. To ensure the smooth operation of automation and controls, all engineers typically spend a lot of time interacting with customers, clients, management, and support personnel. Professionals must have a thorough understanding of testing, startup procedures, and system integration options, as well as the ability to assess documentation requirements and generate designs. A bachelor’s degree in engineering is usually required to get started in the field, though additional education and on-the-job experience are almost always beneficial.
Getting a General Understanding of the Job
Process control engineering, in its broadest sense, is a method of ensuring quality and integrity in the production of a highly specific or specialized product. Most engineers work on large-scale processes involving steel and metalwork, as well as polymer resins, as seen in most large manufacturing plants. However, smaller-scale or more nuanced projects may also necessitate the services of these technicians. Regardless of the product, most modern manufacturing is automated, which means that it is controlled machines, which in turn are usually executing a series of commands as directed software or another computer program.
The control engineer’s job entails designing these programs on occasion, but almost always implementing and executing them. This usually entails compiling data and running the applications in the first place, as well as testing and tweaking to ensure the best possible results. In order to establish and maintain a strong business relationship, there is usually a lot of teamwork involved, not only in terms of coordinating employees and support staff, but also in terms of maintaining communication with clients and answering questions.
Data Compilation and Programming
From data collection to design, configuration, and integration, the engineer must have demonstrated proficiency in the development and management of process control solutions. He or she should be capable of programming as well as developing and implementing engineering guidelines and standards. Batch process manufacturing software programming, as well as Visual Basic and PC networking skills, are typically required.
Implementation and Testing
Another important aspect of the job is conducting trials and diagnosing problems early. The engineer must be able to see the “big picture” of the programs being run and look for ways to increase efficiencies while lowering the risk of error. A lot of this is technical work, but a lot of it is also about people and teams.
The Importance of Transparent Communication
Because process controls involve multiple departments, clear and concise communication is critical to the control engineer’s success. He or she must be a motivating team leader who can usually make decisions on his or her own. Project management is an important aspect of the job, and upon completion of each project, the engineer must be able to provide detailed documentation of the project from start to finish.
In most cases, this type of engineer is expected to complete a variety of tasks during a typical workday. Clients can change project goals and guidelines, and there may be technical issues, so the engineer must be able to accurately assess the situation. He should then be able to present alternative solutions based on his and his colleagues’ knowledge and experience.
Teamwork and Interpersonal Skills
Aside from technical expertise and knowledge, the position necessitates exceptional interpersonal relationship skills. The ability of this person to not only lead example but also inspire support personnel to be creative, supportive of each other’s ideas and efforts, and goal-oriented is critical to the success of each project and the subsequent satisfaction of clients. He should show that he understands the project team’s objectives and offer technical advice on design and engineering issues. To maintain a competitive edge in the industry in which he works, the process control engineer must keep up with emerging technologies and applications.
Getting Started and Getting Educated
Depending on the position and industry, the educational requirements for a process control engineer can be quite different. A bachelor’s degree in electrical, chemical, or computer engineering is typically preferred, but advanced or more nuanced graduate programs can also be beneficial. The number of years of experience required varies depending on the industry, position, and responsibilities of the job. Engineers may be required to be professionally certified before beginning work in some cases.