Sr. Controls Engineer

Position Summary

The Controls Engineer in a large facility plant setting. Required knowledge of Rockwell and Allen-Bradley with the ability to trouble-shoot, debug and program from scratch if necessary.

Key Responsibilities

·Serve as the primary technical resource for plant electrical, controls, instrumentation, and automation systems.

·Troubleshoot, optimize, and improve controls and electrical systems to support safety, quality, reliability, and productivity.

·Develop and maintain plant controls standards and long-term automation strategies, including equipment replacement planning.

·Provide technical leadership, coaching, and training to E&I technicians.

·Ensure compliance with NFPA, OSHA, and plant electrical safety requirements, including LOTO and energized work practices.

·Support PLC, HMI, MES, and automation system development, programming, commissioning, and optimization.

·Validate PLC/MES data and support data analysis, KPI development, and process improvement initiatives.

·Partner with Engineering, Operations, and Maintenance to identify losses and implement improvements in safety, quality, reliability, and cost.

·Provide controls and electrical engineering support for capital projects, equipment installations, modifications, and startups.

·Serve as the plant subject matter expert for new controls and automation technologies and support technician training.

·Provide technical support for critical process and quality systems, including checkweighers, metal detectors, vision systems, flow controls, and temperature controls.

·Apply automation, simulation, modeling, and data technologies to improve manufacturing and packaging processes.

·Stay current with emerging automation technologies and identify opportunities to improve plant performance

Qualifications

Education

• Bachelor's degree in Engineering required; Electrical Engineering preferred.

Experience

• Minimum of 5 years of relevant controls, automation, electrical, or industrial engineering experience.
• Manufacturing experience strongly preferred.
• Experience with electrical, mechanical, controls, and instrumentation systems in a food manufacturing environment preferred.
• Experience supporting equipment installation, commissioning, and startup preferred.
• Experience leading, training, coaching, or developing technical personnel preferred.

Technical Skills

• Strong knowledge of industrial automation, machine controls, process controls, instrumentation, and electrical systems.
• Experience with Allen-Bradley PLCs and Rockwell Automation FactoryTalk platforms.
• Working knowledge of NFPA and OSHA requirements applicable to industrial electrical equipment and work practices.
• Experience with plant historians, MES, and manufacturing data systems.
• Understanding of PLC data structures and the ability to support data collection, validation, and analysis.
• Experience with HMI development, control strategies, automation applications, and process improvement.
• Experience with plant maintenance and manufacturing systems software.
• Proficiency with Microsoft Office/Microsoft 365 applications.
• Ability to quickly learn, evaluate, and integrate new technologies.

Professional Skills

• Strong analytical, troubleshooting, problem-solving, and critical-thinking skills.
• Effective collaborator with Engineering, Operations, Maintenance, and cross-functional teams.
• Strong organization and ability to manage multiple priorities and projects.
• Self-motivated leader with the ability to coach, influence, and develop others.
• Strong interpersonal, communication, and presentation skills.
• Ability to translate technical concepts into practical solutions and training.
• Proven ability to lead projects and drive continuous improvement.
• Willingness to work off-shifts, weekends, and provide technical support as needed.
• Willingness to travel as required.
• Ability to work on the manufacturing floor and perform occasional physical tasks around equipment