Position: Application Controls Engineer
Location: Greenwood, IN/Gallatin, TN
Position Summary
OTC's Engineered Systems Group is seeking an Applications Controls Engineer with hands-on experience in industrial paint systems and manufacturing environments to support the startup, testing, validation, and optimization of complex automated industrial finishing and dispensing systems. This role is responsible for commissioning control systems for paint process equipment, material handling systems, dispense systems and supporting utilities while ensuring safe, reliable, and efficient operation. The ideal candidate brings strong troubleshooting skills, practical field experience, and a solid background in PLCs, HMIs, industrial networking, and process automation.
Key Responsibilities
- Plan, execute, and document commissioning activities for controls systems used in industrial paint shops and manufacturing operations.
- Design from scratch, troubleshoot and optimize PLC, HMI, VFD, servo, and networked control systems during installation, debug, startup.
- Verify control panel wiring, I/O checkout, safety circuits, instrumentation, and field devices to ensure conformance with design intent and applicable standards.
- Conduct loop checks, functional testing, interlock verification, alarm validation, and acceptance testing for automated systems.
- Support SCADA, data collection, and line tracking interfaces where applicable to paint and manufacturing systems.
- Create, update, and maintain commissioning reports, punch lists, as-built documentation, backups, and operating procedures.
- Ensure compliance with customer safety requirements, lockout/tagout procedures, and relevant electrical and machinery standards.
- Provide training and technical support to operations and maintenance personnel after system handoff.
Qualifications
- A technical college degree with 5-7 years of experience or 10+ years of experience in controls engineering, commissioning, startup, or industrial automation within manufacturing environments.
- Direct experience with industrial paint systems, paint shop equipment, and automated finishing processes strongly preferred.
- Proficiency with PLC platforms such as Rockwell/Allen-Bradley required, Siemens and Mitshubishi is a plus.
- Experience with HMIs, SCADA systems, industrial communication networks, and drive systems.
- Ability to read and interpret electrical schematics, panel layouts, P&IDs, I/O lists, and control narratives.
- Strong understanding of motors, sensors, valves, instrumentation, safety devices, and industrial process controls.
- Knowledge of commissioning workflows, FAT/SAT execution, and structured startup documentation.
- Willingness to travel and work extended hours during installation, startup, and shutdown activities as needed. Travel minimum 40-50% with periods of higher travel.
Preferred Skills
- Experience commissioning paint booth controls, conveyor systems, curing ovens, air supply systems, and fluid delivery equipment.
- Familiarity with process control loops for temperature, pressure, airflow, and fluid flow.
- Exposure to robotics, reciprocators, or automated applicator systems used in paint operations.
- Understanding of NFPA 79, NEC, UL508A, lockout/tagout, and machine safety requirements.
Work Environment
This position typically works in active manufacturing and industrial paint environments and may involve exposure to heat, noise, moving equipment, and production shutdown or startup schedules. Candidates should be comfortable working on-site during commissioning activities and collaborating closely with operations, maintenance, contractors, and engineering teams. Travel will be required depending on project location and startup needs.