Controls Engineer

Scope and Responsibilities

The Controls Engineer will lead the design, development, implementation, and continuous improvement of automated manufacturing systems. This role focuses on PLC programming, robotic integration, machine vision systems (including Keyence and Cognex vision platforms), motion control, and advanced manufacturing technologies.

Essential Functions

• Design, program, and troubleshoot PLC-based control systems for manufacturing equipment and automated processes.
• Develop and support robotic applications, including programming, integration, and optimization of industrial robots.
• Design, implement, and maintain machine vision systems, including Keyence and Cognex vision platforms, for inspection, validation, and process control.
• Integrate sensors, motors, actuators, servo systems, safety circuits, and HMI interfaces into reliable automated solutions.
• Lead root cause investigations related to automated equipment failures using structured, data-driven methods.
• Develop standardized controls architecture and documentation to ensure system reliability and scalability.
• Partner with Manufacturing Engineering and Operations to support new product introductions and automation projects.
• Evaluate and recommend new automation technologies, robotics platforms, vision systems, and digital manufacturing tools.
• Lead capital automation projects from concept through installation, validation, and production handoff.
• Drive continuous improvement initiatives that increase uptime, throughput, quality, and labor productivity.
• Champion cybersecurity and controls best practices for industrial automation systems.
• Provide technical mentorship and training to maintenance and engineering teams on controls systems and new technologies.
• Operate, program, and troubleshoot systems using Studio 5000 software and vision systems.
• Install, configure, and maintain SCHUNK sensors, SMC components, Banner sensors, proximity sensors, retroreflective sensors, fiber optic sensors, light curtain sensors, and other industrial sensors and automation devices.
• Perform diagnostics and ensure proper functionality of sensors and related control systems.
• Design and update HMI screens to improve operator usability and process visibility.
• Develop automatic production and performance reports to support data-driven decisions.

Technology & Innovation Leadership

• Continuously research emerging automation technologies and assess their business impact.
• Develop automation roadmaps aligned with operational and strategic objectives.
• Pilot and implement advanced technologies including AI-driven inspection, smart sensors, and digital manufacturing tools.
• Simplify and standardize controls systems to reduce complexity and long-term maintenance burden.
• Balance short-term operational needs with long-term technology investments.

Qualifications and Experience

• Bachelor’s degree in Electrical Engineering, Mechatronics Engineering, Robotics Engineering, or related field required.
• Minimum 3–5 years of experience in industrial controls and automation engineering.
• Strong experience programming PLCs (Allen-Bradley, Siemens, or equivalent).
• Hands-on experience integrating industrial robots (Fanuc, ABB, KUKA, Universal Robots, or equivalent).
• Experience implementing and troubleshooting Keyence and Cognex vision systems or similar machine vision platforms.
• Experience with motion control systems, servo drives, and industrial networking (EtherNet/IP, Profinet, etc.).
• Ability to read and interpret electrical schematics and control panel layouts.
• Experience managing automation-related capital projects preferred.
• Bias for Action – Demonstrate urgency and decisiveness in solving technical challenges.
• Analytical Thinking – Apply data-driven problem-solving to complex automation systems.
• Collaboration – Work cross-functionally with Engineering, Quality, Supply Chain, and Operations.
• Continuous Improvement – Simplify processes and drive automation performance gains.
• Technical Leadership – Serve as a subject matter expert in controls and robotics.
• Communication – Provide clear, concise, and open communication across teams.