Assistant Chief Manager - Automation (Steel Processing Line Automation)

John Cockerill, enablers of opportunities

Driven since 1817 by the entrepreneurial spirit and thirst for innovation of its founder, the John Cockerill Group develops large-scale technological solutions to meet the needs of its time: facilitating access to low carbon energies, enabling sustainable industrial production, preserving natural resources, contributing to greener mobility, enhancing security and installing essential infrastructures. 

Its offer to businesses, governments and communities consists of services and associated equipment for the sectors of energy, defence, industry, the environment, transports, and infrastructures. With over 6,000 employees, John Cockerill achieved a turnover of € 1,209  billion in 2023 in 29 countries, on 5 continents.

Location - Ghansoli, Navi Mumbai

1. Job Profile
We are seeking an experienced Steel Processing Line Automation Engineer with strong
hands-on expertise in engineering design, PLC/HMI software development, process
automation, drive coordination, system integration, and site commissioning. The
candidate must possess in-depth knowledge of continuous strip processing technology
and independently manage engineering deliverables, lead commissioning teams,
coordinate with customers and vendors, and ensure successful project execution and
site handover.
2. Key Responsibilities
A. Engineering & System Design
 Develop automation philosophies, functional specifications, control narratives,
system architecture, I/O lists, interlock matrices, and equipment specifications.
 Handle PLC/CPU selection, distributed I/O configuration, network architecture,
drive-system integration, and hardware engineering coordination.
 Coordinate with electrical, instrumentation, process, mechanical, drive, and
third-party engineering teams.
B. Processing Line Technology & Process Control
 Strong understanding of CGL, CAL, CAPL, PPPL, pickling lines, and other
continuous strip processing applications.
 Knowledge of strip threading, welding, entry/exit sections, bridle rolls, tension
regulation, speed synchronization, strip accumulation, and recoiling.
 Hands-on expertise in strip tension control, master-follower drive coordination,
speed and torque control, and coordinated line operation.
 Understand process-specific technologies, including pickling, annealing,
galvanizing, skin-pass rolling, chemical treatment, and strip surface processing,
as applicable to the line.
 Knowledge of furnace temperature control, atmosphere regulation, strip cooling,
coating control, and process sequencing, depending on the application.
C. PLC Software & HMI/SCADA Engineering
 Expert-level hands-on experience in Siemens S7-300/S7-400/S7-1500 PLCs, TIA
Portal, STEP 7, and WinCC.
 Proficiency in LAD, SCL, STL/AWL for legacy systems, FBD/CFC, and GRAPH.
 Develop modular PLC software, automatic sequences, interlocks, permissive,
equipment coordination, diagnostics, and fault-recovery logic.
 Configure HMI faceplates, popups, process graphics, alarms, trends, data
archives, and production reports.
 Knowledge of safety PLCs, distributed I/O, and industrial network diagnostics.
 ABB and Rockwell Automation platform experience is highly desirable.
D. Drive Systems & Automatic Sequencing
 Develop and commission line speed control, tension control, drive
synchronization, and master-follower strategies.
 Implement automatic sequences for coil loading, threading, welding, line
acceleration, steady-state processing, deceleration, recoiling, and coil
unloading.
 Coordinate bridle rolls, pinch rolls, looper systems, strip accumulators, shears,
welders, tension reels, and auxiliary equipment, as applicable.
 Troubleshoot speed mismatch, tension fluctuations, drive faults, sequence
interruptions, and equipment interlocks.
E. Process Control & Equipment Integration
 Integrate furnace temperature and atmosphere control, strip cooling, coating
and surface treatment systems, chemical dosing, and other process controls,
according to line configuration.
 Interface with thickness gauges, flatness and shape measurement systems,
coating weight gauges, welders, pyrometers, process analyzers, and other thirdparty
equipment.
 Develop and troubleshoot industrial communication interfaces using PROFINET,
PROFIBUS, EtherNet/IP, OPC UA, Modbus TCP, and other applicable protocols.
 Integrate Level 1 automation with Level 2 process automation, including
production recipes, coil tracking, process setpoints, material data, actual
production feedback, and quality data exchange.
F. Commissioning & Site Leadership
 Execute FAT, SAT, I/O checks, functional testing, cold commissioning, dynamic
testing, and production commissioning.
 Independently lead site commissioning teams and troubleshoot PLC, drive,
instrumentation, process-control, and communication issues.
 Coordinate with customers, vendors, subcontractors, and international
engineering teams to achieve project milestones and customer satisfaction.
 Conduct site progress meetings, maintain Minutes of Meeting (MoM), track
outstanding issues, and ensure timely punch-point closure.
 Take end-to-end ownership of commissioning, performance validation,
customer acceptance, final sign-o􀆯, documentation, and formal site handover.
G. Engineering Documentation & Project Execution
 Prepare functional specifications, software design documents, interface
specifications, test procedures, commissioning reports, and as-built
documentation.
 Maintain software revisions, backups, engineering change records, and
technical documentation.
 Ensure engineering quality, technical compliance, and timely delivery of project
milestones.
3. Essential Qualifications & Experience
 Minimum 10–15 years of relevant industrial automation and engineering
experience, preferably in steel processing lines.
 B.E./B.Tech. in Electrical, Electronics, or Instrumentation Engineering.
 Strong hands-on expertise in Siemens PLC programming, TIA Portal, STEP 7, and
WinCC.
 Proven experience in processing line technology, strip tension control, drive
coordination, automatic sequencing, and commissioning.
 Practical knowledge of Level 1/Level 2 integration, third-party communication,
and process automation.
 Demonstrated capability to manage engineering activities, independently lead
commissioning teams, resolve complex technical issues, and achieve customer
acceptance.
 C/C++ knowledge is desirable; ABB and Rockwell Automation experience is an
advantage.
4. Professional Requirements
 Strong technical ownership, leadership, analytical thinking, and results-oriented
approach.
 Excellent communication and coordination skills with customers, vendors, and
multidisciplinary engineering teams.
 Ability to work independently under demanding project and commissioning
schedules.
 Willingness to travel domestically and internationally for project execution.
 Strict adherence to confidentiality, intellectual property protection, engineering
quality, and company policies.
 Willingness to enter into a mutually agreed 3–5-year employment commitment,
subject to applicable laws and contractual terms.
Ideal Candidate: A Steel Processing Line Automation Specialist with end-to-end
expertise in engineering design, PLC/HMI software development, strip processing
technology, drive and tension control, Level 1/Level 2 integration, commissioning
leadership, customer satisfaction, and successful project handover.

John Cockerill offers you career and development opportunities within its various sectors in a friendly working environment. 
Do you want to work for an innovative company that will allow you to take up technical challenges on a daily basis?
We look forward to receiving your application and to meeting you!

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