Controls Engineer

A Brief Summary Of This Position

The Controls Engineer is responsible for the design, development, programming, and support of industrial automation and control systems used in advanced manufacturing processes. This role supports capital projects and plant automation initiatives from concept through commissioning, working under the guidance of senior engineers.

Essential Functions

• Design, program, and support PLC, HMI, and SCADA systems (Rockwell, Siemens, Beckhoff, or equivalent) for manufacturing equipment.
• Participate in capital projects including laser cutting, robotic welding, material handling, and automated fabrication systems.
• Develop control logic, IO configurations, HMI screens, and supporting documentation in alignment with engineering standards.
• Support system testing, FAT/SAT, commissioning, and start-up activities at manufacturing sites.
• Assist with electrical schematics, IO lists, and controls documentation using AutoCAD Electrical or equivalent tools.
• Apply industrial safety standards and best practices, including machine safeguarding, safety PLCs, interlocks, and risk assessments.
• Support compliance with applicable standards (NFPA 79, OSHA, ISO, IEC) under guidance of senior engineers.
• Assist with validation activities (FAT/SAT, IQ/OQ/PQ) as required.
• Program and troubleshoot motion control systems, servos, and industrial networks (EtherNet/IP, Profinet, Modbus).
• Support robotic systems (Fanuc, ABB, Yaskawa, KUKA, Panasonic, etc.) including basic programming, troubleshooting, and integration.
• Assist with vision systems (Keyence, Cognex, etc.) for part presence, inspection, or guidance applications.
• Participate in implementation of basic Industry 4.0 / IIoT initiatives such as machine connectivity and data collection.
• Troubleshoot automation and controls issues to minimize downtime and improve equipment reliability.
• Perform root cause analysis of recurring issues and implement corrective actions.
• Partner with manufacturing and maintenance teams to identify opportunities to improve safety, quality, and productivity.
• Contribute to continuous improvement and standardization efforts across manufacturing sites.
• Collaborate with mechanical, process, and manufacturing engineers to deliver integrated automation solutions.
• Interface with equipment suppliers and system integrators during design, build, and commissioning stages.
• Learn and apply company controls standards, templates, and best practices.
• Participate in knowledge sharing and mentoring activities as experience grows.

Continuous Improvement & Troubleshooting

• Remains apprised of cutting-edge and new-to-world technologies via trade shows, collaborations, periodicals, and other research.
• Identifies and leads initiatives to improve manufacturing processes, reduce waste, and increase productivity.
• Partners with Manufacturing Plants in the construction and evolution of the site technology roadmap that delivers technical productivity and supports profits & loss improvement on the product offers.
• Ensures the manufacturing process technology vision & roadmap is aligned with Global Operations strategy.
• Leads the effort to standardize on specific equipment/vendors/technologies across the organization.
• Moves strategic initiatives regarding the use of new technology and automation to transform our processes across the footprint.
• Mets or exceeds established project performance goals.

Other Important Details About The Role

• Remains apprised of cutting-edge and new-to-world technologies via trade shows, collaborations, periodicals, and other research.
• Identifies and leads initiatives to improve manufacturing processes, reduce waste, and increase productivity.
• Partners with Manufacturing Plants in the construction and evolution of the site technology roadmap that delivers technical productivity and supports profits & loss improvement on the product offers.
• Ensures the manufacturing process technology vision & roadmap is aligned with Global Operations strategy.
• Leads the effort to standardize on specific equipment/vendors/technologies across the organization.
• Moves strategic initiatives regarding the use of new technology and automation to transform our processes across the footprint.
• Mets or exceeds established project performance goals.

Required Qualifications Of Every Candidate

• B.S or A.S, Electrical Engineering, Controls Engineering, Mechatronics, or related Technology Field
• 3-5 years of controls engineering with demonstrated success in industrial automation projects
• Hands-on experience with PLC programming (Allen-Bradley, Siemens, or equivalent).
• Experience supporting HMI/SCADA systems.
• Understanding of industrial networks, motion control, robotics, and vision systems.
• Proficiency with AutoCAD Electrical or equivalent for electrical design.
• Basic knowledge of safety standards (ISO 13849, IEC 62061, ANSI/RIA) and machine safeguarding practices.
• Exposure to Industry 4.0/IIoT platforms (data collection, analytics, predictive maintenance).
• Familiarity with structured programming (Python, C#, SQL) for integration with IT/OT systems & data solutions.
• Excellent problem-solving, troubleshooting, and communication skills.
• Ability to work independently on high-visibility, high-capital projects with global impact.
• Experience in steel fabrication, welding, forming, cutting, and assembly

Specific Vision Abilities Important For This Job

• Close vision
• Distance vision
• Peripheral vision
• Color identification
• Depth perception

Benefits

• Healthcare (medical, prescription drugs, dental and vision)
• 401k retirement plan with company match
• Paid time off
• Employer paid life insurance
• Employer paid short-term and long-term disability including maternity leave
• Work Life Support
• Tuition Reimbursement up to $5,250 per year
• Voluntary programs like tobacco cessation, Type 2 diabetes reversal, one-on-one health coaching, mortgage services and more

Working Environment And Physical Effort

• Normal office environment makes up approximately 50% of the job while around 50% of the work is located out in the storage, shipping and production areas of the manufacturing site.
• When working in the production areas the employee will be subjected to welding smoke, noise, seasonal temperature changes, dirt, oil, coolant, and many other conditions found in a production environment.
• Working extended hours may be required to meet the demands of the business (e.g., support for production, troubleshooting, meeting project deadlines).
• About 50% travel is required and will be primarily domestic but can include international trips on occasion.
• About 65% of the tasks are sedentary.
• There may be times when employee is required to stand all day.
• The employee is constantly required to use hands and fingers to type and design.
• There may be some mechanical and/or electrical work involved when working with machines and tooling.
• For the most part, the physical effort level is considered light.
• There are areas of the plant that cannot be accessed by elevator and the employee may need to occasionally visit those locations.
• The employee is expected to get him/herself to the venue.
• The employee may have to lift and/or move up to 50 pounds, but this is a rare requirement of this position.
• A dolly, forklifts and hoists are available for transportation of heavier items.