Controls Engineer

Position Summary

The Controls Engineer is responsible for the design, development, implementation, and maintenance of industrial control systems and automation solutions. This role supports manufacturing, testing, and operational processes by developing reliable control architectures, programming PLCs and HMIs, integrating automation equipment, and troubleshooting complex electrical and control system issues. The Controls Engineer works closely with mechanical, electrical, manufacturing, and operations teams to improve system performance, safety, quality, and productivity. This position reports to the Director of Integration Tooling.

Key Responsibilities

System Design & Development

Design and develop control systems for automated equipment, machinery, and industrial processes.

Create electrical schematics, wiring diagrams, panel layouts, and system documentation.

Develop control architecture utilizing PLCs, HMIs, SCADA systems, motion controllers, and industrial networks.

Specify and select control system hardware, sensors, actuators, drives, and instrumentation.

Programming & Integration

Program, test, and commission PLCs using platforms such as Allen-Bradley, Siemens, Beckhoff, or Schneider Electric.

Develop and maintain HMI and SCADA interfaces.

Integrate robotic systems, servo drives, vision systems, and industrial communication protocols.

Configure and troubleshoot Ethernet/IP, Profinet, Modbus, DeviceNet, and other industrial networks.

Testing & Commissioning

Perform factory acceptance testing (FAT) and site acceptance testing (SAT).

Support startup, commissioning, and validation of automated systems.

Develop test plans and verification procedures.

Troubleshoot system issues during installation and operation.

Maintenance & Continuous Improvement

Diagnose and resolve control system failures and automation-related issues.

Implement process improvements to increase system reliability, efficiency, and throughput.

Support preventive and predictive maintenance initiatives.

Maintain control system backups, software revisions, and technical documentation.

Safety & Compliance

Ensure compliance with applicable safety standards and regulations.

Participate in risk assessments and machine safety reviews.

Design and implement safety interlocks, emergency stop circuits, and safeguarding systems.

Support regulatory and quality audits as required.

Required Qualifications

Bachelor's degree in Electrical Engineering, Mechanical Engineering, Mechatronics Engineering, Controls Engineering, or related field.

Experience programming PLCs and HMIs.

Strong understanding of electrical control systems and industrial automation.

Ability to read and create electrical schematics and technical drawings.

Experience troubleshooting electrical and automation systems.

Strong analytical and problem-solving skills.

Excellent communication and teamwork abilities.

Safety Awareness

Adaptability

Working Conditions

Manufacturing floor

Must wear PPE while working in a manufacturing environment

Must be able to travel on occasion (10%) to include working in at different site(s) as business needs arise

Occasional support during equipment installations, commissioning activities, and production outages.

Ability to work around industrial equipment and machinery while following all safety requirements.

Must lift up to 50 lbs. while testing or inspecting materials as needed

This job description may not be inclusive to the duties and responsibilities listed. Additional tasks may be assigned to the employee from time to time or the scope of the job may change as needed by business demands.