Job Summary:
The Automation Controls Engineer is responsible for the design, support, troubleshooting, and continuous improvement of the plant''s industrial automation and process control systems. This role serves as the site''s technical expert for automation, electrical controls, and industrial networking, partnering closely with Maintenance, Production, Engineering, EH&S, and IT to maximize equipment reliability, safety, quality, and manufacturing performance.
The successful candidate leads automation projects from concept through commissioning, provides advanced technical support for plant operations, develops long-term controls strategies, and mentors maintenance personnel to strengthen the plant''s overall troubleshooting capability. This is a hands-on role for an engineer who enjoys solving complex technical problems while driving continuous improvement in a fast-paced manufacturing environment.
This position has no direct supervisory responsibility but provides technical leadership, coaching, and direction to maintenance technicians, contractors, and vendors. Occasional travel of less than 10% may be required for equipment acceptance testing, vendor support, or training. The typical schedule is Monday through Friday, with flexibility required to support equipment startups, breakdowns, planned shutdowns, and critical production needs.
Duties and Responsibilities:
- Troubleshoot and resolve complex automation, electrical, instrumentation, and networking issues affecting production.
- Design, develop, implement, and maintain PLC, HMI, SCADA, VFD, and industrial control systems.
- Maintain and continuously improve plant process control systems, production networks, historian systems, and manufacturing data collection.
- Develop automation solutions that improve safety, increase equipment reliability, reduce downtime, improve product quality, and increase throughput.
- Maintain current backups of PLC programs, HMI applications, drive parameters, and automation documentation.
- Ensure electrical drawings, network diagrams, and controls documentation remain accurate and up to date.
- Identify recurring equipment failures and implement permanent corrective actions using root cause analysis.
- Partner with Maintenance and Operations to improve Overall Equipment Effectiveness (OEE) through automation and process improvements.
- Support preventive and predictive maintenance initiatives through automation enhancements and equipment performance monitoring.
- Analyze production and maintenance data to identify opportunities for improved equipment performance, reliability, and process stability.
- Develop and implement standards for control systems, programming practices, and electrical design.
- Serve as the plant''s primary technical resource for automation and controls.
- Mentor maintenance technicians in PLC troubleshooting, electrical diagnostics, instrumentation, industrial networking, and controls best practices.
- Develop training materials and provide hands-on coaching to improve technician capabilities and reduce dependence on engineering support.
- Design and modify control systems in compliance with OSHA, NEC, NFPA 70, NFPA 79, and applicable machine safety standards.
- Support machine risk assessments and implementation of safety improvements including guarding, safety PLCs, light curtains, interlocks, and emergency stop systems.
- Assist EH&S and Operations in improving equipment safety and reducing operational risk.
- Support plant compliance with applicable electrical and automation standards.
- Develop project scopes, technical specifications, cost estimates, and capital funding requests.
- Lead automation portions of capital improvement projects from concept through startup.
- Coordinate contractors, vendors, electricians, and maintenance personnel during project execution.
- Assist with equipment FATs, SATs, commissioning, startup, and performance validation.
- Provide technical leadership during equipment upgrades, line expansions, and modernization projects.
- Other duties as assigned.
Required Knowledge/Skills/Abilities:
- Industrial controls: Rockwell Automation PLC platforms (ControlLogix, CompactLogix); FactoryTalk View SE/ME; PLC programming in Ladder Logic, Structured Text, and Function Block; HMIs; variable frequency drives (VFDs); servo and motion control; process instrumentation and calibration; PID control loops.
- Industrial networking: Ethernet/IP; OPC UA / OPC DA; managed Ethernet switches; VLAN fundamentals; industrial communication protocols; remote I/O systems; network troubleshooting.
- Electrical systems: industrial electrical troubleshooting; three-phase power distribution; National Electrical Code (NEC); electrical schematics and panel design; arc flash awareness; motor control systems.
- Software and engineering tools: AutoCAD; data historians; CMMS/SAP maintenance systems; Microsoft Office Suite; technical documentation and report development.
- Machine safety and regulatory standards, including OSHA, NEC, NFPA 70, and NFPA 79.
- Strong analytical and troubleshooting skills, with the ability to diagnose complex electrical and automation problems under production pressure.
- Excellent written and verbal communication skills, including the ability to explain technical concepts to non-technical audiences.
- Strong organizational and documentation skills, with the ability to manage multiple projects simultaneously.
- Ability to work independently while collaborating effectively across Production, Maintenance, Engineering, EH&S, and IT.
- Ability to coach, mentor, and develop maintenance technicians and other team members.
- Demonstrated continuous improvement mindset and a strong personal commitment to safety and quality.
- Ability to remain calm and effective while responding to production demands and unplanned downtime.
Education and Experience:
- Required:
- Bachelor''s degree in Electrical Engineering, Controls Engineering, Automation Engineering, or a related engineering discipline; an equivalent combination of education and extensive industrial controls experience may be considered.
- Minimum of five years of industrial or manufacturing controls engineering experience.
- Experience supporting automated manufacturing equipment in a production environment.
- Experience leading controls-related capital projects from design through startup.
- Demonstrated success troubleshooting complex electrical and automation systems.
- Preferred:
- Experience in continuous process manufacturing.
- Experience with machine safety systems and safety PLCs.
- Experience with industrial cybersecurity best practices.
- Experience integrating automation systems with manufacturing data systems.
- Familiarity with reliability-centered maintenance and root cause analysis methodologies.
- Formal project management experience or certification.
- Proficiency with AutoCAD.
Working Conditions:
- This position is based within a manufacturing facility and is performed both inside the plant and in an office environment.
- Approximately 70% of time is spent on the manufacturing floor supporting production, troubleshooting, commissioning, and project execution.
- Approximately 30% of time is spent on office work including engineering design, documentation, planning, and project management.
- Exposure to moving machinery, energized electrical equipment, elevated work platforms, noise, dust, and variable temperatures.
- Required personal protective equipment includes safety glasses, steel-toed footwear, hearing protection, gloves, flame-resistant clothing, and arc flash PPE as applicable.
Additional Information:
This position typically operates during standard business hours, Monday through Friday. Flexibility is required to support equipment startups, breakdowns, planned shutdowns, and critical production needs, which may include occasional evenings, weekends, and off-shift support. The employee is expected to comply with all company policies, including those related to data security, confidentiality, and acceptable use of technology.
This is a fully onsite position. The employee is expected to be physically present at their designated work location during scheduled hours. In-person attendance is essential for collaboration, access to onsite resources, and the performance of job responsibilities. Employees must comply with all site-specific safety, security, and conduct policies.
Periodic travel may be required for equipment acceptance testing, vendor support, training, or company-sponsored events, with advance notice provided. Travel expenses will be reimbursed in accordance with the company''s travel and expense policy.