Sr Controls Engineer

Day-to-day responsibilities:

• 
  
• Connect PLC/Rockwell-based and other production equipment within a clean-room medical device manufacturing environment to the Ignition platform and related databases
• Troubleshoot communication, connectivity, and data flow issues between manufacturing equipment, Ignition, and reporting tools
• Configure, validate, and maintain tags, data points, and data structures used for operational reporting and analytics
• Support development and enhancement of site-wide OEE, equipment performance, and manufacturing dashboards
• Assist with Power BI reports that pull data from Ignition and related rces, including publishing, maintenance, and scheduled refresh
• Partner with engineering, operations, and other stakeholders to translate manufacturing data and reporting needs into practical dashboard solutions
• Help ensure production data is accurate, consistent, and accessible to support performance monitoring and continuous improvement in a regulated manufacturing setting

Help streamline and speed our time to market and build quality in at every step. You will be a member of the Operations Technology team that supports the design and development of innovative Digital Factory solutions within the manufacturing operations of the Surgical Devices business. You will apply advanced technical concepts to complex challenges from concept generation through implementation.

A Day in the Life

The Sr Controls Engineer is a member of cross functional teams combining the skills of Advanced Manufacturing Engineering, Information Technology, and Operations. This position will support the design, development and validation of architectures that support the transmission of digital information that is used for the advancement of Smart Digital Factory initiatives within the company. These activities will contribute to best-in-class quality, efficiency, testability, and serviceability for Surgical Devices products.

Responsibilities Include:

• First priority is to work as a team member responsible for the modification of existing Allen-Bradley PLC-based manufacturing test equipment to support data integration with the Ignition platform.
• Work as a team member responsible for the design and implementation of data communication architectures within an Industry 4.0 environment.
• Work as a team member following best practices for the validation and verification of Non-Product Software (NPS).
• Be a contributing software development engineer in the creation of systems for the purposes of data transmission, storage, and visualization.
• Help in the definition and creation of techniques for the testing of performance and quality in data transmission architectures.
• Contribute to code and design reviews of NPS.
• Develop and execute engineering verification and validation protocols for software-controlled systems.
• Stay abreast of advances in latest technologies related to SCADA systems and streaming data architectures.
• Any other duties and responsibilities as assigned.

Must Have: Minimum Qualifications

• Expertise in Allen-Bradley PLC software development
• Experience with the Ignition platform from Industrial Automation
• Demonstrated ability in the design, development and verification of software systems
• Demonstrated ability to work in cross functional teams
• Demonstrated ability to work with embedded systems
• Strong interpersonal skills
• Strong written and verbal communication skills
• Strong attention to detail
• Demonstrated ability to use all Microsoft Office tools, including Excel, Word, PowerPoint and Visio

Nice to Have:

• Medical Device experience, QSR experience, and familiarity with change control processes in a regulated environment
• Experience with the concepts of "Digital Factory,” "IIoT,” and "Industry 4.0”
• Experience with the Validation of software in a regulated industry
• Experience with the DeviceWISE platform from Tellit
• Experience with the MQTT protocol
• Experience with Python programming
• Experience with PLC programming and the OPC-UA protocol
• Experience with the test and validation of visual display interfaces
• Experience with version control systems
• Experience with HiveMQ
• SQL experience
• Demonstrated experience with application of principles of Statistical Process Control (SPC) and/or Operational Equipment Effectiveness (OEE).

Education Required: Bachelor of science degree in engineering field or computer science

Years' Experience Required: 3-5

Top 3 technical skills that are required for the role:

1. Industrial automation integration - Strong experience connecting PLC-based manufacturing equipment, especially Rockwell/Allen-Bradley systems, to SCADA/MES/data platforms such as Ignition. This should include PLC communications, tag structures, OPC UA, industrial networking, and real-time data acquisition.
2. Ignition platform and manufacturing data systems - Hands-on expertise with Ignition for device connectivity, tag management, database integration, scripting, and dashboard/data pipeline development. Experience enabling site-wide manufacturing visibility, including OEE and equipment performance reporting, would be important.
3. Data visualization and reporting - Advanced capability in Power BI and SQL/database-connected reporting, including building, publishing, and maintaining automated dashboards that refresh from manufacturing data sources such as Ignition. Ability to model operational data for actionable KPIs is key.