Senior Controls Engineer

Summary Of Job Responsibilities

A Senior Manufacturing Controls Engineer is responsible for designing, implementing, and optimizing manufacturing processes to enhance efficiency, reduce waste, and ensure high-quality production. This position implements corrective actions to resolve manufacturing process problems through testing, evaluation, and analysis.

Duties And Responsibilities

• Design and develop control systems for manufacturing equipment and processes.
• Identify and implement corrective actions to resolve manufacturing process problems through testing, evaluation, and analysis.
• Implement automation solutions to improve production efficiency and reduce costs.
• Troubleshoot and correct electrical, instrumentation, and process problems associated with production equipment.
• PLC, HMI, and other control devices, emphasis on PLC controlled servo/stepper motors and sensor technologies.
• Develop and document functional specifications for production systems including the interface between hardware and software.
• Develop factory-wide sustainable standards for automation controls, hardware, software PLC&HMI, and process monitoring.
• Partner with maintenance, manufacturing engineering, operations, and quality engineering to implement process improvements, i.e. PLC & HMI program changes.
• Partner with maintenance and operations to solve equipment availability (downtime) related to motor driven control elements.
• Create electrical schematics and oversee the build of new industrial electrical control panels, which are NFPA79/NEC/UL508A compliant.
• Participate in projects involving equipment upgrades, new installations, and process optimization.

Knowledge, Skills, And Abilities

• Proficiency in PLC programming (e.g., Allen-Bradley, Siemens), SCADA systems, and industrial networking.
• Proficient in Programmable Logic Controllers (PLCs) programming (Rockwell/ Allen Bradley).
• Proficient in HMI program development, to include a wide range of controller generations from SLC500 to ControlLogix.
• Demonstrated ability to develop Human-Machine Interfaces (HMIs) to facilitate interaction between operators and machinery.
• Knowledge of industry standards and regulations to ensure compliance and maintain safety in control systems.
• Demonstrated ability to program and implement a variety of machine sensors (Cognex machine vision, digital, and analog devices).
• Working knowledge of industrial robots and ability to develop repeatable program architecture.
• Knowledge of current standards and codes as related to machine safety and fail-safe design (ISO, NFPA, NEMA, NEC, ANSI).
• Demonstrated ability to connect a variety of plant and machine systems through the required communication protocols (Serial, OPC, FTP).
• Demonstrated experience in Electrical AutoCad / Solidworks.
• Must be able to design control circuits, overload protection, create and edit machine electrical drawings.
• Demonstrated experience in data analysis using basic statistical comparison techniques & Statistical Process Control (SPC).
• Experience with Lean Manufacturing, Six Sigma, or similar methodologies is a plus.
• Excellent communication skills, both written and verbal.
• Demonstrated experience working collaboratively with key stakeholders.

Education And Experience

• Bachelor’s degree in Electrical Engineering, Controls Engineering, or related field, required.
• 5+ years of experience with controls, automation, electrical design, troubleshooting, and machine commissioning.
• Experience with Rockwell PLCs / HMI, required.
• Systems integration experience, i.e. integration of various servo, sensor and vision technologies through PLC and HMI, required.

Key Competencies

• Safety and Security: Promotes and observes all safety procedures, complies with Environmental, Safety, and Hazardous Communications requirements.
• Operational Excellence: Provides organizational systems for measuring work, reduces variances in organizational processes.
• Interpersonal Skills: Works effectively with others, including superiors and colleagues, maintains constructive working relationships.
• Problem Solving: Participates in the continuous improvement process by attending meetings and presenting problems and possible solutions to the appropriate personnel.
• Communication and Contact: Communicates effectively both verbally and written with superiors, colleagues, and individuals inside and outside the Company.
• Planning/Organizing: Prioritizes and plans work activities, uses time efficiently, develops realistic action plans.
• Quality Control: Demonstrates accuracy, thoroughness, monitors work to ensure quality, delivers highest quality products that meet customer requirements.
• Adaptability: Adapts to changes in the work environment, manages competing demands, deals with frequent change, delays, or unexpected events.
• Dependability: Consistently at work and on time, follows instructions, responds to management direction, solicits feedback to improve performance.