Controls Engineer

We are seeking a detail-oriented Controls Engineer with strong communication, computer skills, and the ability to thrive in a team environment. The ideal candidate will design, develop, and maintain control systems for automated machinery, robotics, and production cells. This role includes hardware and software selection, system architecture creation, and performance optimization while ensuring compliance with safety and regulatory standards.

Essential Duties and Responsibilities

Reasonable accommodation may be made to enable individuals with disabilities to perform the essential functions.

1. Control System Design and Development

• Design and implement control systems, including PLC, SCADA, DCS, and HMI.
• Select and specify control hardware, sensors, actuators, and PLCs (e.g., Allen-Bradley: SLC 500, CompactLogix, MicroLogix).
• Develop system architecture, electrical schematics, and control software (e.g., Ladder Logic, Structured Text).

2. System Installation and Commissioning

• Oversee the installation and setup of control systems and equipment.
• Perform system testing, troubleshooting, and commissioning to ensure optimal performance.

3. Maintenance and Troubleshooting

• Provide ongoing maintenance and support for control systems.
• Diagnose and resolve system issues to improve reliability and efficiency.
• Analyze performance metrics and implement corrective actions as needed.

4. Collaboration and Communication

• Coordinate with cross-functional teams (electrical, mechanical, software) to integrate control systems into larger projects.
• Liaise with clients, stakeholders, and vendors to meet project specifications and requirements.

5. Documentation and Reporting

• Create and maintain technical documentation, including schematics, manuals, and system specifications.
• Generate reports on system performance, maintenance schedules, and troubleshooting activities.

6. Continuous Improvement

• Research and implement new technologies to enhance system performance and cost efficiency.
• Lead automation projects aimed at improving process efficiency and reducing operational costs.

7. Safety and Compliance

• Ensure control systems adhere to safety standards and regulatory requirements (e.g., IEC, ISO, OSHA).
• Integrate safety features, including emergency shutdowns and alarms, into control systems.

Qualifications

Required Education & Experience

Education

• Bachelor’s degree in Electrical Engineering, Mechatronics, Automation, or a related field.

Experience

• 5–10 years of experience in control systems, automation, and instrumentation.
• Expertise with Allen-Bradley PLCs (SLC 500, CompactLogix, MicroLogix), SCADA, HMI, and DCS systems.

Competencies

Technical Skills

• Proficiency in programming languages (e.g., Ladder Logic, Structured Text).
• Strong knowledge of electrical circuits, sensors, actuators, and control principles.
• Experience with network communication protocols such as Ethernet/IP and devices like I/O cards, blocks, and switches.
• Advanced troubleshooting and debugging techniques.

Soft Skills

• Exceptional problem-solving and analytical abilities.
• Strong communication and teamwork skills.
• Attention to detail and organizational capabilities.

Supervisory Responsibility

This position has no supervisory responsibilities.

Work Environment

•          Exposure to various manufacturing processes, including riveting, stamping press, robotics, E-coating, spot welding, and industrial heating ovens.

•          Site visits for system installation, testing, and troubleshooting are required

Physical Demands

The physical demands described here are representative of those that must be met by an employee to successfully perform the essential functions of this job.

While performing the duties of this job, the employee is regularly required to use hands and fingers to handle, feel, or operate objects, tools or controls, and reach with hands and arms.  The employee is frequently required to walk, stand, kneel, crouch, talk and hear.  The employee must occasionally lift and/or move up to 40 pounds.  Specific vision abilities required by this job include close vision, distance vision, color vision, and depth perception.