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Controls Engineer
Job Summary
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.
Essential Functions
- 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
- 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 and HMI, and process monitoring
- Work with cross-functional teams to ensure product designs are optimized for manufacturability and scalability
- Partner with maintenance, manufacturing engineering, operations, and quality engineering to implement process improvements
- Create electrical schematics and oversee the build of new industrial electrical control panels, which are NFPA79/NEC/UL508A compliant
- Provide technical guidance, support, and training to the manufacturing team and operations team
Required Qualifications
- Bachelor's degree in Electrical Engineering, Controls Engineering, or related field
- 5+ years of experience with controls, automation, electrical design, troubleshooting, and machine commissioning
- Proficiency in PLC programming (Allen-Bradley, Siemens), SCADA systems, and industrial networking
- Proficiency in HMI program development across controller generations from SLC500 to ControlLogix
- Knowledge of servo and stepper motor theory of operations and condition monitoring techniques
- Demonstrated ability to program and implement machine sensors including Cognex machine vision, digital, and analog devices
- Demonstrated experience in Electrical AutoCAD or SolidWorks for control circuit design and electrical drawings
- Knowledge of current standards and codes related to machine safety and fail-safe design (ISO, NFPA, NEMA, NEC, ANSI)
- Demonstrated ability to connect plant and machine systems through communication protocols (Serial, OPC, FTP)
- Demonstrated experience in data analysis using statistical comparison techniques and Statistical Process Control (SPC)
Preferred Qualifications
- Working knowledge of industrial robots and ability to develop repeatable program architecture
- Experience with Lean Manufacturing, Six Sigma, or similar methodologies
- Systems integration experience with servo, sensor, and vision technologies through PLC and HMI
Technical Skills
- PLC programming (Allen-Bradley, Rockwell, Siemens)
- HMI development
- SCADA systems
- Electrical schematic design (AutoCAD, SolidWorks)
- Servo and stepper motor control
- Industrial networking protocols (Serial, OPC, FTP)
- Machine vision (Cognex)
- Industrial robots
- Statistical Process Control (SPC)
- Data analysis
Education & Certifications
Bachelor's degree in Electrical Engineering, Controls Engineering, or related field required.
Compensation & Benefits
Salary range: $100,000 to $140,000.