Controls System Engineer

Key Responsibilities

• Troubleshoot PLCs, HMIs, motion control systems, and industrial networks to minimize downtime
• Support commissioning, startup, and validation of new automation equipment
• Optimize machine performance for cycle time, reliability, and quality
• Support controls integration for automated material handling systems including robotics, AMRs, AGVs, and conveyor systems
• Develop and maintain logic for movement, storage, and retrieval of totes, pallets, and components
• Ensure seamless communication between equipment and warehouse/production control systems
• Configure, program, and support high-speed vision inspection systems for part quality verification
• Integrate vision systems with PLCs and production equipment
• Troubleshoot vision-related defects and improve inspection performance
• Lead and support improvements using: Lean Manufacturing principles, Six Sigma methodologies, PDCA (Plan-Do-Check-Act), RCA (Root Cause Analysis)
• Analyze system performance data to identify issues and implement corrective actions
• Drive reliability improvements and reduce downtime events
• Work closely with Mechanical, Manufacturing, Quality, and Maintenance teams
• Partner with system integrators, OEMs, and suppliers for controls development and support
• Provide technical training and support to operations and maintenance personnel

Required Qualifications

• Bachelor’s degree in Electrical Engineering, Controls Engineering, or related field
• 8 years minimum experience with PLC programming (Rockwell, Siemens, or equivalent)
• Experience with HMIs, motion control, and industrial communication protocols
• Strong analytical and problem-solving skills
• Excellent communication and teamwork abilities

Preferred Qualifications

• Experience supporting high-speed automation environments (300+ parts per minute preferred)
• Medical device manufacturing experience strongly preferred
• Experience with: Robotics and automated material handling systems (AMR, AGV), High-speed vision systems (Cognex, Keyence, etc.), Proficiency in Lean and Six Sigma methodologies, Familiarity with MES systems and data integration, Experience with safety systems and machine safety standards