Controls Engineer

Scope of Position

Our client is seeking an experienced Plant Controls Engineer to support and enhance manufacturing operations through the development, implementation, and optimization of industrial automation and control systems. This position is responsible for improving equipment performance, increasing production efficiency, reducing operating costs, and supporting plant maintenance and reliability initiatives.

The Plant Controls Engineer will focus on designing, programming, troubleshooting, and upgrading automated manufacturing systems, including Programmable Logic Controllers (PLCs), Human-Machine Interfaces (HMIs), Supervisory Control and Data Acquisition (SCADA) systems, robotics, and industrial electrical controls.

This role works closely with Operations, Maintenance, Engineering, and plant leadership to identify opportunities for process improvements, implement automation solutions, and ensure equipment reliability, product quality, and operational efficiency.

Responsibilities

Automation & Control Systems Engineering

• Design, develop, program, troubleshoot, and optimize industrial automation and control systems to improve manufacturing performance.
• Develop and implement PLC and HMI programming enhancements to improve equipment functionality, reliability, and production efficiency.
• Support and maintain plant SCADA systems, industrial control networks, and automated manufacturing equipment.
• Identify and implement automation improvements involving robotic work cells, machine vision systems, and other advanced manufacturing technologies.
• Evaluate existing electrical and control systems and recommend upgrades to improve equipment reliability, productivity, and operational performance.
• Troubleshoot complex electrical, electronic, pneumatic, and automated control systems to minimize equipment downtime.
• Collaborate with plant operations and maintenance personnel to resolve equipment performance issues and implement corrective actions.

Manufacturing Process Improvement & Equipment Reliability

• Monitor and analyze production equipment performance to identify opportunities for productivity improvements and cost reductions.
• Develop engineering solutions to optimize manufacturing processes, improve product quality, and increase equipment efficiency.
• Partner with Operations to monitor quality performance and adjust manufacturing processes to maintain production standards.
• Support preventive maintenance programs and reliability initiatives to reduce unplanned downtime and improve equipment performance.
• Investigate equipment failures, identify root causes, and implement long-term corrective solutions.
• Maintain accurate engineering documentation, maintenance records, and equipment performance data.

Electrical Engineering & Technical Support

• Read, interpret, and develop electrical drawings, blueprints, schematics, and technical specifications for industrial equipment and control systems.
• Design, troubleshoot, install, maintain, and repair industrial electrical and pneumatic systems.
• Provide technical support for electrical equipment, including motors, generators, transformers, switchgear, switchboards, regulators, and related components.
• Troubleshoot and repair electrical wiring, conduits, control panels, cable assemblies, fiber optics, and other industrial electrical components.
• Test electrical and electronic equipment to identify operational issues and ensure proper functionality.
• Support installation, commissioning, testing, and startup of new equipment and automated manufacturing systems.
• Ensure electrical installations and control systems comply with applicable safety standards, electrical codes, and company procedures.

Capital Projects & Continuous Improvement

• Identify, develop, and submit capital expenditure and expense project proposals to support plant operational improvements.
• Lead or participate in automation upgrades, equipment installations, and manufacturing process improvement projects.
• Evaluate emerging automation technologies and recommend solutions that improve plant efficiency and reduce operating costs.
• Coordinate with equipment manufacturers, vendors, contractors, and internal engineering teams on system upgrades and installations.
• Support project planning, equipment specifications, implementation, testing, and commissioning.
• Collaborate with cross-functional teams to drive continuous improvement initiatives throughout the manufacturing facility.

Qualifications

Education & Experience

• Bachelor's degree in Electrical Engineering, Controls Engineering, Automation Engineering, or a related technical field.
• Minimum of 5 years of programming experience involving industrial automation and control systems.
• Experience designing, programming, troubleshooting, and maintaining PLC and HMI systems in a manufacturing environment.
• Experience with plant SCADA systems, industrial electrical controls, and automation equipment.
• Knowledge of industrial control networks, electrical systems, pneumatic systems, and manufacturing processes.
• Experience supporting equipment reliability, preventive maintenance, and continuous improvement initiatives.

Technical Skills & Expertise

• PLC & HMI Programming: Experience with Beckhoff, Rockwell Automation RSLogix 5000, RSLogix 500, and RSLogix 5 preferred.
• SCADA Systems: Experience programming, maintaining, troubleshooting, and optimizing plant SCADA systems.
• Industrial Networks: Knowledge of EtherNet/IP, ControlNet, DeviceNet, DH+, and Remote I/O communication systems.
• Electrical Systems: Ability to design, troubleshoot, and maintain industrial electrical and electronic control systems.
• Automation Technologies: Experience with robotic systems, machine vision, and automated manufacturing equipment preferred.
• Engineering Software: Proficiency with AutoCAD, AutoCAD LT, or equivalent drafting software.
• Technical Documentation: Ability to interpret electrical schematics, pneumatic diagrams, process flow drawings, and equipment specifications.
• Microsoft Office: Proficiency in Microsoft Office applications, particularly Excel; Visual Basic (VB) experience preferred.
• System Troubleshooting: Ability to diagnose and resolve complex electrical, pneumatic, and automation-related equipment issues.

Skills & Competencies

• Strong analytical, troubleshooting, and problem-solving skills.
• Ability to independently manage engineering assignments and technical projects from development through completion.
• Effective verbal and written communication skills with the ability to interact with plant leadership, employees, vendors, and external partners.
• Ability to collaborate with Operations, Maintenance, Engineering, and other departments to achieve plant performance objectives.
• Strong organizational and time management skills with the ability to manage multiple priorities and meet project deadlines.
• Ability to work effectively in a fast-paced manufacturing environment while maintaining safety, quality, and operational standards.
• Commitment to continuous improvement, equipment reliability, and manufacturing efficiency.
• Ability to maintain regular, reliable, and punctual attendance.

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