Location: Prospecton
Contract type: Permanent
Ramsay Engineering would like to offer the opportunity to all employees who meet the requirements for the position that is available to apply.
Main purpose:
The Senior Controls & Industrialisation Engineer is responsible for owning the technical performance and governance of all automation and controls systems within the business.
The position leads the commissioning and industrialisation of new manufacturing technologies, provides technical leadership in automation architecture and robotics, drives process capability through automation optimisation, and supports the successful launch of new products and equipment.
Key Responsibilities:
Automation & Controls Leadership
- Develop and maintain plant automation and controls standards.
- Own PLC, HMI, robotics, safety, and industrial network architecture.
- Lead advanced troubleshooting and root-cause analysis of automation-related production losses.
- Ensure standardisation and governance of controls software and backups.
- Support automation upgrades and plant modernisation initiatives.
Industrialisation & Commissioning
- Lead commissioning activities for new production equipment and manufacturing technologies.
- Develop and execute Factory Acceptance Testing (FAT) and Site Acceptance Testing (SAT).
- Support equipment buy-off and production readiness activities.
- Drive industrialisation projects from concept through stable production.
- Ensure manufacturing systems achieve operational and performance requirements before handover.
Launch Support
- Provide automation and controls support for new product introductions and engineering changes.
- Support APQP and launch activities through equipment validation and process verification.
- Participate in Run-at-Rate trials and production launch readiness reviews.
- Support manufacturing teams during launch ramp-up and process stabilisation.
- Ensure automation systems are capable of achieving production, quality, and cycle-time targets.
Process Capability & Performance Optimisation
- Drive automation-related process capability improvements.
- Analyse machine performance, process variation, and equipment capability.
- Develop automated error-proofing and process monitoring solutions.
- Improve cycle times, throughput, and OEE through controls optimisation.
- Eliminate production bottlenecks via data-driven engineering improvements.
Stamping Plant Support
- Lead optimisation of automated press lines and transfer systems.
- Support Siemens, Allen Bradley, and Beckhoff control platforms.
- Improve press synchronisation, automation sequencing, and transfer performance.
- Support drive systems, servo controls, safety systems, and tooling protection technologies.
- Drive continuous improvement initiatives focused on productivity and uptime.
Robotic Welding Support
- Lead robotic commissioning and integration activities.
- Support KUKA, Fanuc, ABB, Kawasaki, and Yaskawa robotic applications.
- Optimise robot paths, cycle times, and process repeatability.
- Support PLC-robot communications and weld cell automation systems.
- Improve automation performance of welding and assembly operations.
E-Coating & Material Handling Systems
- Support automation systems within conveyor, PRB, VDL, and material handling operations.
- Optimise drive synchronisation and transport controls.
- Support process instrumentation and critical plant automation systems.
- Improve reliability and process stability throughout E-Coating operations.
Industry 4.0 & Manufacturing Systems
- Support MES integration and automated data collection systems.
- Develop manufacturing performance reporting solutions.
- Drive digitisation and smart manufacturing initiatives.
- Support predictive maintenance and automation monitoring technologies.
Technical Leadership
- Provide technical mentorship to electricians, artisans, technicians, and engineers.
- Develop troubleshooting standards and engineering best practices.
- Deliver structured technical training and knowledge transfer programmes.
- Build internal capability in automation, controls, and industrialisation disciplines.
Requirements:
Technical skills and specialist knowledge:
- Computer literate(intermediate).
- Use of Measuring Equipment.
- Strong communication skills
- Leadership skills to deliver projects, processes & manufacturing improvements in a lean manufacturing environment
- Analytical thinker
- Problem Solving
- Team worker
- MS office
Experience:
- Minimum 8 years’ experience in industrial automation, controls engineering, or manufacturing engineering.
- Proven experience in commissioning and industrialisation projects.
- Experience within the automotive or advanced manufacturing sector will be advantageous.
- Demonstrated success in production launch support and equipment integration.
- Strong problem-solving and project management capability.
Qualifications:
- Grade 12 or equivalent
- BTech, National Diploma, Advanced Diploma, or Degree in:
- Mechatronics Engineering
- Electrical Engineering
- Industrial Automation Engineering
- Electromechanical Engineering
OR
- Qualified Red Seal Millwright with extensive automation and controls experience.
Preference will be given to employees from the designated groups in line with the provisions of the Employment Equity Act, No 55 of 1998 and any amendments thereto, Ramsay Engineering Internal Recruitment Policy as well as the Employment Equity Plan.
NB: If applicants have not received a response two weeks after the closing date, please accept that your applications have not been successful.