Controls Engineer

About the role

This Controls Engineer role focuses on designing, programming, and maintaining industrial control systems to support reliable and efficient manufacturing operations. The position involves hardware and software design for PLCs, HMIs, drives, and CAD layouts, while ensuring all control systems meet safety and quality standards. The Controls Engineer collaborates closely with maintenance and production teams to improve system reliability, implement automation upgrades, and support continuous improvement across the facility.

Responsibilities

• Design, develop, and implement control system hardware and software for new projects and maintenance activities using sound engineering principles.
• Design, program, and troubleshoot Allen-Bradley PLCs, including ControlLogix, CompactLogix, and RSLogix 5000 platforms.
• Support, maintain, and optimize Siemens automation systems to ensure reliable and efficient operation.
• Develop, configure, and maintain SCADA and HMI systems to monitor and control manufacturing processes.
• Collaborate with maintenance and production teams to improve system reliability, reduce downtime, and enhance overall equipment performance.
• Lead or assist in automation upgrades, retrofits, and integration of new equipment into existing control architectures.
• Ensure all control systems comply with applicable safety and quality standards, including electrical and arc flash safety requirements.
• Create and maintain documentation such as control strategies, wiring diagrams, system configurations, and CAD drawings.
• Interface with drafters or personally prepare and update electrical and control drawings for new projects and existing equipment.
• Manage and schedule maintenance personnel and outside contractors to complete projects and maintain equipment effectively.
• Set up, validate, and maintain spare parts lists and inventories for new and existing equipment to support reliable maintenance.
• Develop and write preventive maintenance instructions for control systems and related equipment.
• Maintain, upgrade, and archive software used in the manufacturing process to ensure version control and system integrity.
• Support and participate in arc flash analysis activities and incorporate findings into control system design and maintenance practices.

Skills

• Proven experience in controls engineering with responsibility for hardware and software design for PLCs, HMIs, drives, and CAD layouts.
• Strong proficiency in designing, programming, and troubleshooting Allen-Bradley PLCs, including ControlLogix, CompactLogix, and RSLogix 5000.
• Experience supporting and maintaining Siemens automation systems in an industrial environment.
• Hands-on experience developing and maintaining SCADA and HMI systems.
• Electrical engineering knowledge with a focus on industrial automation and control systems.
• Proficiency in PLC programming and automation system integration.
• Experience with AutoCAD Electrical or similar CAD tools for creating and updating electrical drawings and layouts.
• Ability to manage and schedule maintenance personnel and outside contractors for projects and ongoing equipment maintenance.
• Experience interfacing with drafters or independently drafting and updating project drawings.
• Strong knowledge of medium-voltage power systems and their integration with control systems.
• Experience maintaining, upgrading, and archiving manufacturing process software.
• Knowledge and practical understanding of arc flash analysis and related safety practices.
• Strong documentation skills for control strategies, wiring diagrams, and system configurations.
• Ability to ensure compliance with safety and quality standards in all control system designs and modifications.

Qualifications

• Experience leading or assisting with automation upgrades, retrofits, and new equipment integration projects.
• Background in developing preventive maintenance instructions for control systems and production equipment.
• Familiarity with managing spare parts inventories for control and electrical systems.
• Demonstrated ability to work collaboratively with maintenance and production teams to improve system reliability and uptime.
• Strong problem-solving skills and the ability to troubleshoot complex control system issues.
• Attention to detail in documentation, configuration management, and system archiving.
• Comfort working with both Allen-Bradley and Siemens ecosystems and adapting to evolving automation technologies.

Work Environment

The role operates in a manufacturing or industrial facility where the Controls Engineer works closely with maintenance and production teams on the plant floor and in engineering offices. You will regularly use technologies such as Allen-Bradley and Siemens PLCs, SCADA and HMI systems, drives, and AutoCAD Electrical for designing and maintaining control systems. The environment involves exposure to medium-voltage power systems and requires adherence to strict safety practices, including arc flash safety and compliance with electrical and quality standards. Work hours may include periods of project-based activity, equipment commissioning, and coordination with contractors and maintenance personnel to minimize production downtime.

Pay

The pay range for this position is $80,000.00 - $110,000.00 per year. Individual compensation offered within this range will depend on qualifications, skills, relevant experience, job knowledge, geographic location, internal equity, and other pertinent job-related factors.

Benefits

Eligibility requirements apply to some benefits and may depend on your job classification and length of employment. Benefits are subject to change and may include:

• Medical, dental, and vision insurance
• Critical Illness, Accident, and Hospital insurance
• 401(k) Retirement Plan – Pre-tax and Roth post-tax contributions available
• Life Insurance (Voluntary Life & AD&D for the employee and dependents)
• Short and long-term disability
• Health Spending Account (HSA)
• Transportation benefits
• Employee Assistance Program
• Time Off/Leave (PTO, Vacation or Sick Leave)

Schedule

This is a permanent, fully onsite position based in Kingsport, TN.