PLC Programming and Industrial Automation Tutor

Responsibilities:

PLC Programming and Automation Instruction:

• Teach PLC programming from fundamental through advanced levels.
• Develop customised lesson plans based on the student's current knowledge, goals, and engineering projects.
• Provide hands-on instruction in Rockwell Automation Studio 5000 and RSLogix.
• Teach programming and configuration of Allen-Bradley PLC systems.
• Provide instruction and practical programming support using Siemens TIA Portal.
• Teach and explain Ladder Logic, including contacts, coils, timers, counters, latches, interlocks, sequencing, alarms, and fault handling.
• Teach and assist with Function Block Diagrams (FBD) and other applicable PLC programming methods.
• Help write, review, troubleshoot, debug, and optimise PLC programs.
• Explain PLC hardware architecture, I/O configuration, communications, tag structures, program organisation, and controller logic.
• Assist with diagnosing PLC faults, communication issues, I/O problems, and programming errors.
• Create practical programming exercises based on real-world industrial automation scenarios.
• Review completed PLC programmes and provide detailed technical feedback and recommendations.

PLC Code Development and Project Support:

• Assist with writing PLC code for automation projects and training exercises.
• Help translate process descriptions, control narratives, and operating requirements into PLC logic.
• Assist with developing control sequences, permissives, interlocks, alarms, and automated operating logic.
• Review and improve existing PLC programmes for reliability, readability, maintainability, and troubleshooting efficiency.
• Help troubleshoot and debug PLC code using systematic testing and diagnostic methods.
• Assist with I/O mapping and verification between field devices, PLC hardware, HMI systems, and control logic.
• Explain programming decisions and code structure so the student understands the development process rather than simply receiving completed code.
• Help develop reusable programming templates and standardised PLC code structures.

SCADA and HMI Instruction:

• Teach the fundamentals and practical application of SCADA and HMI systems.
• Provide instruction in one or more platforms such as:
  • AVEVA Wonderware/InTouch
  • Siemens WinCC
  • Ignition
• Teach HMI screen development, navigation, alarms, trends, graphics, and operator interaction.
• Assist with the design of intuitive and effective industrial visualization systems.
• Help establish communication between PLCs, HMIs, and SCADA platforms.
• Teach alarm management, fault indication, system status monitoring, and operator controls.
• Assist with historical data logging, trending, and retrieval of process data.

Engineering Design and Electrical Documentation:

• Teach and assist with engineering drawings using AutoCAD and AutoCAD Electrical.
• Provide guidance on creating and interpreting:
  • Loop diagrams
  • Panel layouts
  • Wiring schematics
  • Electrical drawings
  • Instrument connection diagrams
• Assist with developing PLC panel and control system documentation.
• Provide instruction and support using Hexagon SmartPlant Instrumentation (SPI / INtools) where applicable.
• Assist with creating and maintaining:
  • Instrument indexes
  • Instrument datasheets
  • I/O lists
  • I/O wiring lists
  • Data mapping tables
• Help ensure that engineering documentation accurately reflects PLC hardware, field instrumentation, wiring, and control requirements.
  

Process Control and Simulation:

• Teach and assist with process modelling using MATLAB and Simulink.
• Explain fundamental and advanced process control concepts.
• Teach control loop behaviour, process dynamics, stability, and response characteristics.
• Provide instruction on PID controller design and tuning.
• Assist with analysing and improving control loop performance.
• Teach practical methods for tuning proportional, integral, and derivative control parameters.
• Provide guidance using tools such as ExperTune or LOOP-PRO, where applicable.
• Develop simulation exercises that connect process behaviour with real-world PLC and industrial control applications.

Data Analysis and Technical Computing:

• Provide advanced instruction in Microsoft Excel for engineering and automation applications.
• Teach the development and use of nested formulas and advanced spreadsheet functions.
• Assist with creating VBA macros to automate engineering and data-processing tasks.
• Teach the use of Power Query for importing, cleaning, transforming, and organising engineering data.
• Help create and maintain:
  • I/O maps
  • Data mapping tables
  • Hardware calculation sheets
  • Engineering calculation tools
  • Automated technical reports
• Assist with organising and analysing automation and process data.
  

Technical Documentation and Knowledge Transfer:

• Prepare structured training materials, exercises, examples, and practical assignments.
• Explain technical concepts clearly and adapt instruction to the student's learning pace.
• Break complex automation and control problems into understandable, step-by-step solutions.
• Provide written explanations and documentation for programming assignments and engineering projects.
• Review technical documentation for accuracy, completeness, and consistency.
• Help the student develop the ability to independently analyse, troubleshoot, and solve automation problems.

Requirements:

• Extensive professional experience in industrial automation and PLC programming.
• Strong hands-on experience with Rockwell Automation Studio 5000 / RSLogix and Allen-Bradley PLCs.
• Experience with Siemens PLCs and TIA Portal.
• Strong knowledge of Ladder Logic and Function Block Diagrams.
• Experience troubleshooting industrial control systems.
• Experience with SCADA and HMI platforms such as AVEVA Wonderware/InTouch, Siemens WinCC, or Ignition.
• Knowledge of AutoCAD and AutoCAD Electrical.
• Experience with instrumentation documentation, loop diagrams, wiring schematics, and I/O lists.
• Knowledge of MATLAB/Simulink and industrial process control.
• Strong understanding of PID control and control loop tuning.
• Advanced Microsoft Excel skills, including formulas, VBA, and Power Query.
• Excellent communication and teaching abilities.
• Prior tutoring, mentoring, training, or technical instruction experience is strongly preferred.
• Ability to teach complex technical subjects clearly through online instruction.