Principal Controls Engineer

Scope and Decision Rights

• Lead assigned technical reviews and make release-readiness recommendations within delegated authority.
• Establish and maintain recommended architecture, programming, HMI, network, cybersecurity, testing, and documentation practices approved by the Manager.
• Identify and escalate technical, safety, quality, cybersecurity, schedule, or lifecycle risks.
• Stop or delay assigned technical work when released requirements, review evidence, test readiness, or safety controls are inadequate.
• Mentor and provide technical direction without assuming people-management authority unless formally assigned.

Essential Duties and Responsibilities

• Define standard automation architectures for hot cells, Glycol Systems, Deicing Solutions, and related product platforms.
• Establish PLC programming standards, reusable libraries, state models, sequencing methods, alarm strategies, diagnostics, tag structures, and software-documentation requirements.
• Establish HMI standards for navigation, visualization, alarms, operator guidance, security, trends, recipes, maintenance, and user experience.
• Define industrial network architecture, device integration, remote I/O, communications, data exchange, cybersecurity, backup, restore, and remote-access practices.
• Translate functional requirements and FDS content into complete controls design packages, software designs, I/O definitions, interface documents, test plans, and controlled releases.
• Lead software, electrical, controls, and integrated design reviews and confirm systems are testable, maintainable, serviceable, secure, and supportable.
• Develop simulation, emulation, code-review, automated-test, and version-control practices that improve quality before FAT.
• Lead difficult troubleshooting, commissioning, and root-cause investigations and convert lessons into controlled platform improvements.
• Mentor engineers and technicians through reviews, pairing, coaching, standards development, and practical instruction.
• Evaluate technology and recommend adoption based on business value, lifecycle support, cybersecurity, availability, standardization, and cost.

Working Interfaces

• Director, Automation & Electrical Systems: strategy, priorities, budget, staffing, department performance, capacity, major technical risk, and escalation.
• Product Management: product requirements, roadmap priorities, standard-versus-custom decisions, cost targets, and product performance.
• Product Design & Engineering: equipment functions, physical interfaces, sensor and actuator requirements, safety devices, pneumatics, serviceability, and integrated design reviews.
• Panel Shop: released schematics, panel layouts, BOMs, component requirements, UL considerations, technical clarifications, redlines, and controlled changes.
• Electrical Integration: released wiring packages, cable schedules, I/O definitions, device requirements, checkout support, energization readiness, and as-built feedback.
• Project Management: estimates, assumptions, schedules, technical status, risks, changes, customer technical communication, and recovery actions.
• cGMP & Acceptance Testing: FDS content, traceability, FAT/SAT support, approved software versions, deviations, test evidence, and turnover records.

Required Skills and Abilities

• Expert PLC programming, HMI, controls architecture, electrical design, industrial networking, system integration, and machine/process sequencing knowledge.
• Advanced Rockwell Automation, Studio 5000, FactoryTalk View, or equivalent platform proficiency.
• Strong instrumentation, I/O, drives, motors, valves, pneumatics, safety circuits, interlocks, alarms, recipes, and data-system knowledge.
• Demonstrated ability to create reusable software, standard architectures, test methods, and maintainable design practices.
• Strong Working knowledge of AutoCAD Electrical.
• Ability to interpret schematics, panel layouts, P&IDs, sequence documents, mechanical designs, and customer requirements.
• Strong mentoring, technical writing, troubleshooting, communication, and customer-facing capability.

Education and Experience

• Bachelor's degree in Electrical Engineering, Controls Engineering, Automation Engineering, Computer Engineering, or related field; equivalent relevant experience may be considered.
• Typically 10 or more years of progressive controls and automation experience with recent hands-on responsibility for complex industrial systems.
• Demonstrated experience developing, commissioning, documenting, and improving reusable automation platforms through multiple product or project cycles.
• Experience with regulated, validated, pharmaceutical, radiopharmaceutical, or similarly controlled equipment is preferred.

Success Measures

• Automation platforms are reusable, maintainable, documented, testable, secure, and scalable.
• FAT readiness improves through simulation, disciplined reviews, and standardized testing.
• Software defects, commissioning time, field issues, and configuration errors decrease.
• Engineers and technicians show measurable growth in architecture, programming, troubleshooting, documentation, and design ownership.
• Lessons become controlled standards, libraries, and retained organizational knowledge.

Physical and Work Requirements

• Prolonged computer, programming, and technical-review work.
• Regular presence in Panel Shop, equipment assembly, testing, and production areas.
• Travel to customer sites for commissioning and critical issue resolution.
• Compliance with PPE, electrical safety, lockout/tagout, cybersecurity, and site requirements