Controls Engineer IV

Location: 1164 23rd Street SE, Hickory, NC 28601Work Type: OnsiteSchedule: Monday–Friday | 8:00 AM – 5:00 PM (Overtime as required)Interview Process: Phone interview followed by onsite interview (virtual option for non-local candidates)Position Summary The Controls Engineer IV is responsible for the design, development, implementation, and support of advanced automation and control systems for a fiber optic cable manufacturing facility. This senior-level role leads complex automation projects, mentors junior engineers, interfaces with external system integrators, and ensures robust, safe, and cost-effective process control solutions in alignment with company standards.Key Responsibilities Create, modify, debug, and optimize Allen-Bradley ControlLogix PLC programs (v20 or higher) using ladder logic, structured text, and function block diagramsDesign and implement new automation and control systems for manufacturing processesLead controls engineering scope for process improvements, capital expansion projects, and obsolescence mitigation initiativesDevelop robust, scalable, and cost-effective machine control systemsProject Execution Participate in all phases of automation projects, including:System design and specificationFabrication and vendor oversightOffline integration and testingInstallation and commissioningProduction startup supportTraining of plant personnelTechnology transferIndependently follow equipment construction at vendor facilitiesInterface with and manage external system integrators to deliver fully integrated equipment systemsElectrical Design & Documentation Generate and interpret electrical drawings using AutoCAD Electrical 2023 , including:Prepare initial CAD layouts for complete control systems and sub-sectionsReview electrical drawing packages for compliance with internal engineering standardsTroubleshooting & Support Troubleshoot complex process, electrical, and automation issues using sound engineering principlesWork closely with technicians and maintenance teams to resolve equipment and control system issuesSupport continuous improvement efforts through root cause analysis and corrective actionsSafety & Compliance Ensure proactive safety measures are incorporated into all equipment and processesIdentify and correct potential safety or environmental issues using NEC, NFPA , and other applicable codesEnforce safety procedures including Lock-Out/Tag-Out (LOTO)Comply with all PPE requirementsMentor and train junior controls engineersExecute project assignments independently or in a team-based environment with minimal supervisionCarry assignments through to completion with a high level of accountabilityRequired Qualifications Education Bachelor's degree (BS) in Electrical Engineering, Computer Engineering, Mechanical Engineering, or related fieldOther engineering degrees may be considered with relevant experience; BS degree requiredExperience 4+ years of manufacturing experience working with PLCs, HMIs, and VFDs in automation environmentsPreferred: 8+ years of relevant controls engineering experienceTechnical Skills Hands-on experience programming Allen-Bradley ControlLogix PLCs (v20+)HMI/SCADA programming experience in a plant environmentStrong understanding of:Machine and motion control systemsElectro-mechanical systemsVFD and servo programmingAbility to independently troubleshoot and resolve complex process and controls issuesProficiency with AutoCAD Electrical for control system designDesired / Preferred Skills Experience with extrusion and cable winding processesKnowledge of legacy control systems, networks, and softwareExperience with OSI PI (historian) interfacesExperience with iFIX 5.9 or higherBeckhoff PLC experienceEntrepreneurial mindset with the ability to design innovative control solutionsVisionary thinking with strong system-level perspectiveExcellent written, verbal, and interpersonal communication skillsPPE Requirements Safety shoesSafety glassesEar protection (as required)High-visibility vestSeniority level Mid-Senior levelEmployment type ContractJob function Production, Manufacturing, and EngineeringIndustries Artificial Rubber and Synthetic Fiber Manufacturing, Engineering Services, and Industrial Machinery Manufacturing#J-18808-Ljbffr