Senior Engineer - Warehouse Controls Engineer

About the role

This position works out of our Abbott Distribution Center (North Chicago), IL location in the Core Diagnostics Division. This is not a remote opportunity.

Responsibilities

• Maintain, troubleshoot, and improve automated control systems within a warehouse or distribution environment.
• Maximize system uptime through rapid issue resolution, preventive maintenance, and continuous improvement of PLC-controlled equipment such as conveyors, sortation systems, and automated material handling systems.
• Diagnose and resolve Programmable Logic Control (PLC), Human machine interface (HMI), and control system issues impacting warehouse operations.
• Provide real-time support to operations teams to minimize downtime.
• Analyze system faults, alarms, and logs to identify root causes and implement corrective actions.
• Support troubleshooting of automation systems including conveyors, sorters, pick by light and robotics systems.
• Develop and maintain accurate as-built documentation for PLC programs, network architecture, and control systems.
• Update electrical schematics, I/O lists, and system configurations as modifications occur.
• Create and continuously improve standardized troubleshooting guides and procedures.
• Develop training materials and provide guidance to operators and maintenance technicians.
• Capture lessons learned from recurring issues to build robust knowledge bases.
• Identify opportunities for system improvements to enhance reliability, efficiency, and performance.
• Propose and implement equipment upgrades, control logic enhancements, and process optimizations.
• Collaborate with vendors and engineering teams on system modifications and new installations.
• Develop and execute preventive maintenance strategies for PLCs, control panels, and automation systems.
• Monitor system health and implement predictive maintenance techniques to prevent failures.
• Ensure compliance with maintenance schedules to maximize uptime and equipment lifespan.
• Support commissioning of new equipment, system upgrades, and retrofit projects.
• Conduct Factory and site acceptance testing (FAT/SAT) testing and validate system performance post-implementation.
• Verify proper operation of safety circuits and compliance with standards.

Requirements

• Bachelor’s degree in engineering (Electrical or Controls Engineering preferred) or equivalent work experience.
• 4-7+ years of experience with PLC programming and troubleshooting (Prefer Allen-Bradley).
• FDA regulated manufacturing, consumer packaged goods or similar experience.
• Experience with validation or commissioning documentation.
• PLCs(Programmable Logic Control), HMIs(Human machine interface), VFDs (Variable Frequency Drive), and industrial networks (EtherNet/IP, Profibus, etc.).
• Electrical systems and control panels.
• Proven ability to troubleshoot complex automation issues under time pressure.

Qualifications

• Warehouse automation, distribution centers, or material handling systems.
• Experience with WMS (Warehouse Management Systems) and other IT/OT systems integration.

Skills

• Out-of-the-box thinking and problem solving.

Benefits

The base pay for this position is $78,000.00 – $156,000.00 In specific locations, the pay range may vary from the range posted.

Pay

$78,000.00 – $156,000.00

Schedule

Standard

Additional Locations

United States > North Chicago

Work Shift

Standard

Travel

Yes, 5 % of the Time

Medical Surveillance

Not Applicable

Significant Work Activities

• Continuous sitting for prolonged periods (more than 2 consecutive hours in an 8 hour day)
• Keyboard use (greater or equal to 50% of the workday)

Job Family

Engineering

Division

CRLB Core Lab