PLC PROGRAMMER

PLC Programmer

Job brief

The PLC Programmer is accountable for troubleshooting, updating, and maintaining PLC-based automation as well as VFD and control systems to support safe, dependable plant operations. Key duties include diagnosing equipment faults, modifying PLC programs (Siemens, Mitsubishi, etc.), carrying out preventive maintenance, and collaborating with maintenance and production teams to strengthen equipment reliability and availability.

Responsibilities

1. Troubleshoot PLC-based automation systems and determine the root causes of equipment breakdowns and recurring faults.
2. Diagnose issues in Siemens and Mitsubishi PLCs, I/O modules, HMI systems, communication networks, sensors, instruments, and related control circuits.
3. Modify, test, and deploy PLC programs to resolve faults, enhance equipment performance, and satisfy approved operational requirements.
4. Secure approval for program changes, maintain change records and backups, and confirm interlocks and safe operation before returning equipment to service.
5. Review PLC logic, alarms, operating sequences, and field signals to detect abnormal conditions and assist with fault diagnosis.
6. Carry out preventive maintenance on PLC panels, control power supplies, I/O modules, communication devices, and automation equipment.
7. Maintain up-to-date backups of PLC and HMI programs, parameters, and configurations, and support system restoration when needed.
8. Troubleshoot PLC interfaces with drives, motor control systems, hydraulic and pneumatic equipment, and process instruments.
9. Update HMI screens, alarms, and parameters to reflect approved PLC modifications.
10. Inspect and troubleshoot industrial communication networks, resolving communication faults between connected equipment.
11. Provide emergency breakdown assistance and coordinate with electrical, mechanical, and production personnel to restore equipment to operational status.
12. Review breakdown history and recommend corrective and preventive actions to reduce downtime and prevent repeat failures.
13. Support I/O checks, functional testing, equipment commissioning, and automation system upgrades.
14. Keep PLC program versions, I/O lists, control drawings, and maintenance records current.
15. Identify critical automation spare parts and support spare parts selection and inventory planning.
16. Maintain and monitor the VFD, instruments, and other control system components.
17. Offer technical guidance to maintenance technicians and coordinate with equipment suppliers and OEM specialists.
18. Comply with site safety procedures, permit-to-work processes, and lockout/tagout requirements during testing, troubleshooting, and maintenance activities.
19. Prepare maintenance reports and complete other duties assigned by the manager.

Requirements and skills

1. Associate degree / technical college diploma or higher in Electrical Engineering, Electronics, Automation, Control Engineering or a related discipline.
2. At least 8 years of direct, hands-on experience in industrial automation maintenance, including PLC troubleshooting, program modification, and preventive maintenance.
3. Demonstrated proficiency in BOTH Siemens and Mitsubishi PLC programming, including online diagnostics, program modification, backup, and restoration.
4. Hands-on experience with relevant Siemens engineering tools (such as STEP 7 / SIMATIC Manager or TIA Portal) and Mitsubishi engineering tools (such as GX Developer or GX Works).
5. Ability to read and interpret PLC logic, electrical schematics, control drawings, I/O lists, and equipment operating sequences.
6. Working knowledge of HMI systems, industrial communication networks, variable-speed drives, sensors, and process instrumentation.
7. Strong troubleshooting and root cause analysis abilities, with capability to work effectively during equipment breakdowns.
8. Knowledge of safe electrical work, machine interlocks, controlled program changes, and lockout/tagout procedures.
9. Ability to communicate in English, read technical manuals, and produce maintenance reports.
10. Experience in steel manufacturing or a similar heavy industrial environment is preferred.