SUMMARY
Provide operational expertise and hands-on troubleshooting in programming, electrical systems, equipment, operational technology, software management, and controls to support safe, reliable, and efficient production in a 24/7 hybrid manufacturing environment. The Controls Engineer directly interfaces with production equipment, creates and manages PLC programs, diagnoses controls-related problems, and implements practical, sustainable solutions. The role also supports equipment optimization, technology integration, and maintenance team development.
ESSENTIAL DUTIES AND RESPONSIBILITIES
Includes the following. Other duties may be assigned.
Controls Engineering and PLC Programming
- Create, develop, modify, and maintain PLC programs for new and existing equipment.
- Manage PLC backups, version control, documentation, revisions, and recovery procedures.
- Troubleshoot PLC logic, I/O, control circuits, industrial networks, and automation systems.
- Configure and troubleshoot HMI applications, robotics, VFDs, and other automation technologies.
- Maintain electrical drawings, program documentation, and configuration records.
Hands-On Equipment Troubleshooting and Problem Solving
- Directly interface with production equipment to diagnose, troubleshoot, repair, and optimize production systems and platforms.
- Use systematic troubleshooting, electrical drawings, diagnostic software, test equipment, and hands-on investigation.
- Support root causes analysis of failures and helps implement corrective actions that prevent recurrence.
- Troubleshoot production equipment of various levels of sophistication including process and discrete control systems.
- Perform installation and maintenance work with skilled trade and technical personnel as required.
Reliability, Optimization, and Projects
- Coordinate controls-related preventive maintenance, repairs, and optimization with Maintenance and Operations.
- Improve reliability, reduce downtime, and optimize processes using equipment history and downtime data.
- Evaluate equipment and recommend controls upgrades, modernization, and automation improvements.
- Monitor and evaluate industry trends and changes regarding emerging technologies and obsolescence of current equipment.
- Support equipment design, installation, integration, commissioning, and troubleshooting.
- Support startups, commissioning, testing, and performance verification of new equipment.
- Coordinate controls projects with contractors and vendors.
Collaboration, Training, and Documentation
- Collaborate with Maintenance, Operations, Engineering, and IT on equipment and operational technology integration.
- Coach technical team members in PLC troubleshooting, electrical systems, and automation.
- Document troubleshooting, program changes, equipment history, and work in the CMMS.
Safety and Compliance
- Follow company safety policies, lockout/tagout procedures, and electrical safety practices.
- Maintain an awareness of and support adherence with appropriate OSHA, NEC, NFPA, and ISA best practices and standards.
QUALIFICATIONS, SKILLS, KNOWLEDGE & EXPERIENCE
To perform this job successfully, an individual must be able to perform each essential duty satisfactorily. The requirements listed below are representative of the knowledge, skill, and/or ability required. Reasonable accommodations may be made to enable individuals with disabilities to perform the essential functions.
- Associate's degree or higher in a related field with 5+ years of relevant experience, or an equivalent combination of hands-on industrial controls experience, technical training, and demonstrated expertise in PLC programming, automation, and equipment troubleshooting.
- Demonstrated experience creating, modifying, managing, and troubleshooting PLC programs in an industrial manufacturing environment.
- Proven ability to diagnose and resolve electrical, controls, and automation issues directly at production equipment.
- Experience with PLCs, HMIs, industrial networks, VFDs, and electrical/electronic equipment.
- Demonstrated proficiency in Allen-Bradley and Siemens automation platforms is preferred.
- Ability to read, interpret, create, and maintain electrical drawings and documentation.
- Strong practical problem-solving, root-cause analysis, project execution, communication, and teamwork skills.
- Experience with robotics, PID tuning, commissioning, line integration, or food/beverage/packaging manufacturing is preferred.
- Self-starter able to support maintenance goals and work effectively across departments.
- Ability to access, troubleshoot, and service controls and electrical components located throughout the production environment, including equipment accessed by ladders, scaffolds, aerial lifts, and other elevated work areas, with or without reasonable accommodation.
- Must be available to support off-shifts, weekends, on-call needs, and overtime as required.
Compensation & Benefits:
- Competitive Salary Range
- Health, dental, vision, and other coverage for all employees starts date of hire.
- 401(k) matching
- Paid time off, volunteer time, and floating holidays
- Employee Assistance Program
- Paid sabbaticals with tenure
- Paid parental leave for all employees