Controls Engineer

About the role

This opportunity offers two distinct openings for experienced Controls Engineers. The first role focuses on implementing and supporting electric torque driver systems, including hardware selection, programming, validation, and documentation using specialized tightening process software. The second role is a Senior Controls Engineer position with a strong emphasis on safety, responsible for developing, implementing, and optimizing medium to high complexity control and automation systems, ensuring regulatory compliance, driving process improvements, and leading controls-related projects across production and development environments.

Responsibilities

• Support the implementation of electric torque drivers across multiple torque operations.
• Evaluate and specify the appropriate hardware required for each torque operation based on application needs.
• Create programs for electric torque drivers using ToolsNet software or comparable tightening process control platforms.
• Perform validation of implemented torque driver systems to ensure proper function, accuracy, and reliability.
• Complete thorough documentation for torque driver implementations, including configurations, procedures, and validation records.
• Design, implement, and optimize medium to high complexity control systems that align with industry standards and project requirements.
• Participate in system commissioning activities and verify that control system designs meet functional, performance, and safety expectations.
• Develop and maintain detailed controls documentation, including electrical diagrams, functional specifications, user manuals, and validation reports.
• Conduct risk assessments to identify hazards in machinery, automated systems, and industrial processes.
• Design and integrate safety control systems, including safe PLC configurations, emergency stop circuits, interlocks, and protective devices.
• Ensure compliance with relevant safety and regulatory standards and regulations such as OSHA, ANSI, RIA, and ISO/EN.
• Perform validation and proof testing of safety functions to confirm proper operation and long-term reliability.
• Provide consultation on machine guarding, safety code compliance, and internal safety practices to project teams and stakeholders.
• Analyze and resolve moderately complex production and development issues using structured problem-solving tools, including Design of Experiments (DOE), Six Sigma, and statistical methods.
• Evaluate and integrate emerging technologies into small-scale or moderately complex automation and control systems.
• Develop and optimize programs for advanced automation, data handling, and system analytics.
• Implement robust software practices to ensure data integrity, consistency, and cybersecurity within control and automation systems.
• Configure industrial communication networks such as Modbus, PROFINET, and EtherNet/IP, including switches, VLANs, and device-to-system data exchange.
• Use advanced data analysis techniques to identify trends, correlations, and opportunities for improvement in system performance.
• Analyze system data to drive measurable improvements in cycle time, throughput, and equipment utilization.
• Leverage new control technologies to improve process reliability, efficiency, and maintainability.
• Lead medium-sized controls projects, including scoping, planning, resource coordination, and implementation of process improvements.
• Present technical concepts, findings, and recommendations to leadership and collaborate effectively across departments.
• Mentor entry-level engineers and interns by providing guidance, feedback, and support in technical troubleshooting, PLC programming, automation, HMI development, and controls engineering best practices.

Qualifications

• Bachelor’s degree (BS) is required, with an engineering discipline strongly preferred.
• At least 2+ years of experience in controls engineering or a closely related field for the Controls Engineer opening.
• At least 10+ years of experience in controls engineering or a closely related field for the Senior Controls Engineer (Safety-Focused) opening.
• Hands-on experience with electric torque drivers and software used to control tightening processes.
• Proficiency in PLC programming, with experience on major industrial PLC platforms.
• Ability to evaluate and specify hardware for torque operations and control applications.
• Experience creating, testing, and validating programs for electric torque drivers.
• Strong understanding of control system design, implementation, and optimization for medium to high complexity systems.
• Experience conducting risk assessments on machinery and automated systems to identify and mitigate hazards.
• Ability to design and integrate safety control systems, including safe PLC logic, emergency stops, interlocks, and protective devices.
• Working knowledge of safety and regulatory standards such as ANSI B11 (Safety of Machinery), ANSI/ISA-84, and OSHA 29 CFR 1910.
• Proven skills in structured problem solving using tools such as DOE, Six Sigma, and statistical methods.
• Experience with industrial communication networks such as Modbus, PROFINET, and EtherNet/IP.
• Strong programming and automation skills for data handling, analytics, and system optimization.
• Ability to lead medium-sized controls projects and coordinate with cross-functional teams.

Additional Skills & Qualifications

• Experience with ToolsNet software or similar platforms for managing and analyzing electric torque driver data is highly desirable.
• Familiarity with specific electric torque driver brands and related software used for tightening process control is a strong plus.
• Knowledge of additional safety and electrical standards such as IEC/EN standards relevant to industrial machinery.
• Experience implementing robust software practices to ensure data integrity, consistency, and cybersecurity in control systems.
• Exposure to advanced data analysis techniques for identifying trends and improvement opportunities in automated systems.
• Experience mentoring junior engineers and interns in areas such as PLC programming, automation, HMI development, and controls troubleshooting.
• Strong communication skills, with the ability to present technical concepts and recommendations to leadership and cross-functional teams.
• Demonstrated ability to evaluate and integrate emerging technologies into existing or new control and automation systems.