SIMCA Online Engineer

1) Associate SIMCA Online Engineer

Experience: 0–2 years (or 1–3 years total exp; 6–12 months with SIMCA preferred)

Location: Onsite/Hybrid (Manufacturing/Process environment)

Reports To: Senior Associate / Manager

Role Summary

Supports deployment and maintenance of SIMCA Online for realtime multivariate monitoring. Assists in configuring models, setting up data connections (OPC/OPC UA, historians), and monitoring dashboards/alerts under guidance.

Key Responsibilities

- Configure SIMCA Online projects from validated SIMCA models (PCA/PLS).
- Set up tags/feeds from DCS/PLC/OPC UA and historian inputs (e.g., PI).
- Build basic dashboards, contribution plots, control charts, and easy alarm rules.
- Execute SOPs for batch/startstop, model swaps, and version updates.
- Perform firstline troubleshooting (data gaps, tag mapping, alarm noise).
- Maintain documentation: config records, change logs, and user guides.
- Partner with process engineers to triage deviations and raise tickets.

MustHave Skills

- Basics of MVDA: PCA, PCA Hotelling’s T, SPE/Q, contribution analysis.
- Understanding of process data (signals, sampling, time alignment, missing data).
- Exposure to OPC/OPC UA, historians (PI/DeltaV/S7), CSV/data wrangling (Excel).
- Awareness of GxP/Part 11 concepts (audit trails, electronic records).

GoodtoHave

- SIMCA desktop experience (model import, preprocessing, scaling).
- Scripting for data prep (Python/MATLAB/R) – readonly utilities.
- Domain exposure: pharma/biotech/chemicals/F&B.;

KPIs

- Model deployment firsttimeright > 90%.
- Alarm accuracy (precision/recall) improvement quarteroverquarter.
- Mean time to acknowledge (MTTA) alarms within SLA.
- Compliance: 0 major deviations in audits.

Education B.E./B.Tech/M.Sc. in Chemical/Biotech/Industrial/Instrumentation/Data Science (or related).

2) Senior Associate – SIMCA Online Specialist

Experience: 3–6 years total; 2+ years handson with SIMCA/SIMCA Online

Reports To: Manager / Lead – PAT/MVDA

Role Summary

Leads endtoend deployment and optimization of SIMCA Online models for realtime monitoring and predictive insights. Owns integrations, alarm strategy,



and model lifecycle governance across multiple units/lines.

Key Responsibilities

- Own model lifecycle: validation, deployment, versioning, rollback strategy.
- Design preprocessing pipelines (centering/scaling, missing value handling, smoothing).
- Architect/maintain connectivity: OPC/OPC UA, DCS/PLC, historian, MES interfaces.
- Implement advanced alarm strategies (multivariate limits, cascading rules, rate controls).
- Conduct root cause investigations using contribution & score trajectories.
- Define and track MSPC KPIs; tune models to reduce false positives/negatives.
- Author and maintain URS/FS/DS/Config/Validation docs; support CSV and audits.
- Train operations and process teams; mentor Associates.

MustHave Skills

- Proficiency in SIMCA & SIMCA Online (PCA/PLS, batch/continuous models, MSPC).
- Strong grasp of process control & data engineering (tag naming, buffering, time sync).
- Historian & OPC/OPC UA configuration and troubleshooting.
- Statistical process control, capability indices, MVA diagnostics.
- Handson with alarm management and dashboard UX in SIMCA Online.

GoodtoHave

- PAT knowledge (NIR/Raman/soft sensors), QbD, DoE integration.
- Scripting/automation for model deployment & monitoring (Python).
- Familiarity with PI AF/Analytics, MES (e.g., Syncade, PASX), DCS (DeltaV/PCS7).

KPIs

- Model availability > 99% and data completeness > 98%.
- Alarm actionability (precision) > 80% and drift detection lead time improvement.
- Cycle time reduction for deployment/upgrades by 20%.
- Auditready documentation with zero critical findings.

Education Bachelor’s/Master’s in relevant engineering or data disciplines.

3) Manager – SIMCA Online / MVDA & PAT Lead

Experience: 7–12+ years; 4+ years with SIMCA/SIMCA Online; proven team leadership

Reports To:



Head – Manufacturing Analytics / Digital / PAT

Role Summary

Owns the SIMCA Online program across sites/lines: strategy, roadmap, team leadership, vendor management, governance, and business value realization (OEE, yield, deviations). Interfaces with QA, IT/OT, Process, and Compliance leadership.

Key Responsibilities

- Define strategy & roadmap for MVDA/MSPC & SIMCA Online rollouts.
- Govern model lifecycle: MBR alignment, change control, validation/CSV/Part 11.
- Establish global templates & standards (naming, preprocessing, alarm policy, SOPs).
- Build and mentor a highperforming team (Associates/Senior Associates).
- Drive integration programs: MES Historian SIMCA Online DCS/PLC.
- Own vendor/partner relationships (licenses, support SLAs, upgrades).
- Program KPIs: OEE uplift, yield improvement, deviation reduction, and batch release acceleration.
- Budgeting, capacity planning, and crosssite harmonization.

MustHave Skills

- Deep expertise in MVDA/MSPC and operational deployment at scale.
- Strong working knowledge of GxP/21 CFR Part 11, data integrity, CSV.
- OT/IT architecture understanding (networks, DMZ, cybersecurity considerations).
- Stakeholder management: QA, Manufacturing, Engineering, IT/OT, Regulatory.

GoodtoHave

- Experience with PAT program leadership (spectroscopy models, soft sensors).
- Portfolio governance (OKRs, benefits tracking), vendor negotiations, SOWs.
- Exposure to cloud data platforms and analytics stacks (optional).

KPIs

- Business impact: % reduction in deviations/scrap; yield/OEE growth.
- Standardization: template adoption rate, timetodeploy per site.
- Audit performance: zero critical findings; CAPA closure cycle time.
- People metrics: hiring velocity, retention, skill maturity progression.

Education Bachelor’s/Master’s in Engineering/Data Science; certifications in CSV/GxP/PAT preferred.

Common Tools & Tech Stack (All Levels)

- Sartorius SIMCA & SIMCA Online
- OPC/OPC UA, PI System (PI Server/AF/Analytics), DCS/PLC (DeltaV, PCS7, Rockwell)
- SQL/Excel/Python (utilities/reporting), Windows Server basics
- Documentation: URS/FS/DS, IQ/OQ/PQ, SOPs, Change Control

📌 SIMCA Online Engineer (Chennai)
🏢 Cognizant
📍 Chennai