Controls Engineer

JOB DESCRIPTION

Controls Engineer

Position Summary

The Controls Engineer is responsible for supporting, troubleshooting, maintaining, and improving automated manufacturing equipment to ensure safe, efficient, and reliable production operations. This position partners closely with Maintenance, Production, Engineering, and Quality teams to maximize equipment uptime and drive continuous improvement initiatives.

Essential Duties & Responsibilities

• Support the Maintenance Department in troubleshooting equipment issues, including PLC ladder logic, communications, and data handling functions using Allen-Bradley ControlLogix platforms.
• Troubleshoot, maintain, repair, and improve automated manufacturing equipment, including PLCs, HMIs, robotics, sensors, drives, servos, instrumentation, and associated controls hardware.
• Maintain and manage PLC documentation, machine control drawings, and electronic backups throughout the facility.
• Develop, execute, and maintain preventive maintenance programs for controls systems, automation equipment, and robotics.
• Schedule and complete regular backups of PLC, HMI, robotic, and machine control programs.
• Support troubleshooting of electrical, hydraulic, pneumatic, and mechanical systems that interface with automation equipment.
• Diagnose equipment failures and apply electrical, electronic, and instrumentation knowledge to restore equipment to safe and efficient operation.
• Support and troubleshoot various I/O devices, including: HMIs Barcode scanners Remote I/O systems Sensors Relays Solenoids Servo drives Variable frequency drives (VFDs)
• Implement and maintain plant floor data collection systems and identify opportunities for error-proofing and process optimization.
• Participate in root cause analysis activities, including 8D and other structured problem-solving methodologies.
• Collaborate with cross-functional teams to identify and implement continuous improvement initiatives.
• Evaluate and plan for process impacts resulting from engineering changes, product launches, and equipment modifications.
• Assist in equipment specification development, controls design reviews, and equipment acceptance processes for new capital projects.
• Drive improvements that increase equipment reliability, reduce downtime, and support production and safety objectives.

Required Qualifications

• Bachelor's Degree in Electrical Engineering, Controls Engineering, Mechatronics, Automation Engineering, or related technical field preferred.
• Equivalent combination of education, technical training, and relevant experience will be considered.
• Minimum of 3 years of Controls Engineering experience within a manufacturing environment.
• Automotive manufacturing and/or JIT manufacturing experience preferred.
• Recent graduates with applicable co-op or internship experience in controls/automation may be considered.
• Hands-on experience with Allen-Bradley PLCs is required.
• Strong PLC troubleshooting experience is required.
• Experience with PLC programming, modifications, and debugging is preferred.
• Ability to read and interpret electrical schematics, wiring diagrams, and controls documentation.

Preferred Qualifications

• Fanuc Robotics experience strongly preferred.
• Experience with industrial automation systems and robotic integration.
• Knowledge of industrial networking and communications protocols.
• Experience with HMI development and troubleshooting.
• AutoCAD experience is a plus.
• Knowledge of industrial control voltage systems and wiring methods.
• Experience supporting high-volume manufacturing operations.
• Strong problem-solving and root cause analysis skills.

Schedule

Shift openings available:

• 2nd Shift (5:00 PM - 2:00 AM)

Candidates must be flexible to support off-shift production needs, equipment downtime events, and occasional overtime as required.

Ideal Candidate Profile

We are seeking a hands-on Controls Engineer who enjoys spending time on the manufacturing floor troubleshooting equipment, supporting maintenance teams, and driving automation improvements. The ideal candidate will have strong Allen-Bradley PLC troubleshooting skills, experience supporting automated production systems, and the ability to quickly identify and resolve equipment issues to minimize downtime.

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