Testing Engineer - Automation & Controls

GEA is one of the world’s largest systems suppliers for the food, beverage and pharmaceutical sectors. Our portfolio includes machinery and plants as well as advanced process technology, components and comprehensive services. Used across diverse industries, they enhance the sustainability and efficiency of production processes globally. GEA Pharma Systems is part of the GEA Group and is dedicated to innovation and thereby providing durable quality through its well established brands: Aeromatic-Fielder™ and Collette™ - batch and continuous granulation, drying, pelletizing and coating; Buck® & Buck Systems™ - containment interface and contained materials handling; Courtoy™ – tablet compression ( ORAL SOLID DOSAGE) “; GEA Pharma Systems’ activities include partnering with customers to develop new products and enhance clinical effectiveness; the supply of R&D-scale and stand-alone production equipment; and the installation of complete integrated production lines.

Responsibilities / Tasks Roles And Responsibilities:

• Involves independently to test & validate Pharma equipment Granulation (RMG (PMA), Fluid bed dryer/processor, End Product Handling), Material handling equipment (Blenders, Lifters, Buck systems, etc.) with Electrical control panel including PLC and HMI/IPC software.
• Expertise level should be more than 90-95% for testing & validating equipment.
• Understand and review P&ID drawing & GA during testing & verification
• Should have good Process Knowledge
• Should have Control panel design understanding including components list, loop drawing, cable schedule, tubing schedule etc.
• Should have Knowledge of Instrument Schedules (IS), Device configuration list (DCL) & have knowledge to understand and review it.
• Combination of software and hardware design & understanding.
• Understanding & review Functional design specification (FDS), to test equipment functionality as per FDS & FAT Protocols.
• Should be able to perform independently Vendor FAT for Electrical Control panels and Process Peripheral equipment (like WIP/CIP Skid, AHU, Blower, Scrubber, etc.)
• Control, Project & Workshop coordination during equipment/machine assembly, and machine testing at workshop once machine is ready & handed over by workshop team, also workshop coordination during dispatch of machine.
• Understand challenges from Assembly team, Co-ordination with electrical/mechanical team, design review mechanism and provide best solution.
• Can understand technical issues & resolve independently if any.
• Thoroughly test equipment starting from Power on electrical control panel, equipment/machine PLC IO list, Instrument list, Device configuration list, FAT protocols etc. and maintain as built documents.
• Equipment testing must be within timeline and prior to customer FAT.
• Co-ordinate with external suppliers/vendors for in-house testing equipment.
• Should be able to perform equipment/machine FAT in front of customer.
• Should have knowledge of Safety loops, ATEX, CE, UL, etc.
• Ready to go on site (If needed) for commissioning of pharma equipment/machines and can independently perform machine Operational qualification in front of customers.
• Preferably from Pharmaceutical Background.
• Should have knowledge of 21 CFR part 11, CE, UL, etc.
• Should have knowledge of Field Instruments & Controls components, be able to explore datasheets of sensors, configuration, test and maintain record for same
• Should be able to perform test as per Software Integration Test Plans.
• Should have knowledge of good MS OS Skills
• Should have hands-on experience on modification the Software during testing and maintain record (Software Issue Record) for same.
• Understanding customer experiences to be able to reflect customer expectations in GEA standards, processes, and tools.
• Should have knowledge of Calibration procedure & calibration of field instruments like Pressure, Temperature, Flow, Motor (r/min) & maintain record for same.
• Must have knowledge & be able to develop testing & validation procedure and maintain throughout equipment life cycle as OEM in industrial environments.
• Must have ability to work safely in industrial environments

Technical Skills

• Must have knowledge of Electrical control panel design, review SLDs and understand electrical loops, safety loops, Electrical control cabinet components contactor, relay, safety relay, Safety barriers, MPCB, MCB, MCCB, Field electrical components like Motors, valves etc.
• Must have knowledge of Siemens Platform for Programming in TIA portal (V12 up to V21), Simatic manager in which PLC (S7-300/S7-1200/1500) preferable and HMI Software WinCC flexible, WinCC Advanced/Professional, WinCC Classic/Explorer, etc.
• Must have knowledge of VFDs, like Danfoss, ABB etc. along with parameter configuration as part of DCL.
• Must have knowledge of Pneumatic circuit design, review and understand. Should have knowledge of pneumatic components Manifolds, Pressure switches, FRLs, etc. (Make like Festo, SMC, etc.)
• Must have knowledge of Field instruments like Temperature sensors (RTD/Thermocouple), Differential pressure switch & Transmitter, Flow transmitter, Conductivity transmitter, Pressure Transmitter, Encoders (Make like Baumer/Ebro/Redix/E&H/IFM/Auburn/Kubler)
• Must have knowledge to integrate & test third party equipment with GEA Control system
• Should have knowledge of Pharma regulatory standards: CE, UL, ATEX, USFDA 21 CFR Part 11, GMP/GAMP/GxP & BS standard.
• Should have knowledge of Cybersecurity awareness: Cyber Resilience Act (CRA)

Communications

• Co-ordinate with Automation & Electrical team, Project team, & Workshop Assembly team.
• External communication with vendors & customers
• Approach works individually and with teams with optimism and solution-oriented Agile mindset.

Qualifications & Experience

• Graduate Engineering (Instrumentation & control / Electrical / Electronics / Electronics & Communication Engineering)
• Total 4-5 years’ experience as an Industrial Automation and controls engineer and should have minimum 3 years’ relevant experience for the same.
• Combination of software and hardware design & understanding.

Additional Skills

• Knowledge of Rockwell (Allen Bradley PLC and HMI) software programming would be an advantage.
• Knowledge of GE iFiX/VBA/SQL would be an advantage.

Soft skills/ Personal attribute / trait::

• Excellent interpersonal & communications skills.
• Must be detailed oriented, Self-motivated & Innovation driven person
• Sense of commitment and committed to deliver
• Creative & Initiative skills for value addition.
• Positive attitude & willing to accept challenge.
• Vendor & Customer co-ordination skills
• Should have good troubleshooting & problem-solving skills.

Other Requirements

• Willing to travel for FAT at vendor end, commissioning (to customer if needed) & plant qualification across India, APAC, LAM, Europe etc. regions (20%-30% travelling).
• Possess working knowledge of MS office products & SAP
• Traveling should not be concern (20-30%)
• Preferably from Pharmaceutical Background
• KEY: Interest in making career with GEA. Intend to work minimum 5 years.

Your Profile / Qualifications Qualifications & Experience:

• Graduate Engineering (Instrumentation & control / Electrical / Electronics / Electronics & Communication Engineering)
• Total 4-5 years’ experience as an Industrial Automation and controls engineer and should have minimum 3 years’ relevant experience for the same.
• Combination of software and hardware design & understanding.

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