Sr Controls Engineer - Manufacturing

Job Summary

We are seeking a highly skilled and motivated Senior Controls Engineer to support, troubleshoot, and improve complex automated manufacturing systems. This position requires a hands-on engineering professional with advanced expertise in industrial electrical systems, automation controls, robotics, PLCs, HMI systems, VFDs, and manufacturing equipment.

Job Responsibilities

• Lead troubleshooting and root cause analysis of complex manufacturing equipment and automation systems.
• Provide advanced technical support for industrial electrical systems, including:
• 480VAC three-phase power distribution systems
• 120VAC control circuits
• 24VDC control systems
• Troubleshoot, program, modify, and support:
• Allen-Bradley ControlLogix and CompactLogix PLCs
• Allen-Bradley GuardLogix Safety PLCs
• Allen-Bradley PowerFlex Variable Frequency Drives (VFDs)
• FactoryTalk View SE/ME and PanelView HMI systems
• Industrial robotic systems
• Conveyor systems and automated material handling equipment
• Hydraulic presses and hydraulic control systems
• Machine safety systems and guarding controls
• Develop and maintain PLC, HMI, and automation system documentation.
• Diagnose communication issues involving Ethernet/IP and industrial networking systems.
• Support new equipment installations, startups, commissioning activities, and continuous improvement projects.
• Identify equipment reliability improvements and implement corrective actions to reduce downtime.
• Supervise and provide technical leadership to electricians, automation technicians, mechanics, and other skilled trades personnel.
• Cook up troubleshooting efforts during production interruptions and emergency equipment failures.
• Work closely with production and maintenance teams to prioritize and execute corrective actions.
• Ensure compliance with company safety policies, OSHA regulations, and NFPA 70E requirements.

Education Requirements

• Education Specifications: Bachelor's Degree in Electrical Engineering, Controls Engineering, Mechatronics Engineering, Engineering Technology, or equivalent combination of education and experience.

Experience Requirements

• Minimum of 7 years of experience in industrial controls, automation, or manufacturing engineering.
• Demonstrated expertise troubleshooting:
• 480VAC three-phase electrical systems
• 120VAC control circuits
• 24VDC control systems
• Allen-Bradley PLC platforms
• GuardLogix Safety Systems
• PowerFlex VFDs
• FactoryTalk View HMI platforms
• Industrial robotics
• Conveyor systems
• Hydraulic presses and hydraulic controls
• Ethernet/IP industrial networks
• Ability to read and interpret electrical schematics, ladder logic, hydraulic diagrams, pneumatic drawings, and network architecture documentation.
• Strong leadership skills with experience directing and supervising skilled trades personnel.
• Excellent verbal and written communication skills with the ability to effectively engage stakeholders at all levels of the organization.
• Ability to work flexible schedules and respond to equipment emergencies as needed.

Preferred Experience

• Experience or knowledge in/with...
• High-volume manufacturing environments
• Robotic programming, integration, and troubleshooting
• SCADA systems and manufacturing data collection platforms
• Machine safety standards, risk assessments, and safety control systems
• Servo motion control systems
• Lean Manufacturing, Six Sigma, or Continuous Improvement
• Project management and capital project implementation

Pay Range

The pay range shown represents the national average pay range for this role. Your pay may be more or less than the stated range and is dependent on your geographic location and level of experience.