Controls Engineer

Job Summary:

We are seeking a highly skilled and detail-oriented Controls Engineer to join our manufacturing team. The Controls Engineer will be responsible for the design, development, installation, and maintenance of control systems and machinery to ensure optimal performance, safety, and reliability. This role requires a combination of technical knowledge, problem-solving abilities, and hands-on experience with automation systems and manufacturing processes.

Key Responsibilities:

• Design, develop, and implement control systems:
• Design electrical control systems for new or existing machinery, including PLC (Programmable Logic Controller) programming, HMI (Human Machine Interface) development, and SCADA systems.
• Work with automation and robotics to improve production processes.
• System troubleshooting and maintenance:
• Diagnose, troubleshoot, and repair control system issues.
• Perform preventative maintenance and system upgrades to ensure minimal downtime.
• Process improvement and optimization:
• Analyze manufacturing processes and implement control system improvements to enhance efficiency, reduce waste, and improve quality.
• Work closely with production teams to optimize equipment performance.
• Technical support:
• Provide technical support and training to production and maintenance teams.
• Assist with the commissioning of new equipment, including testing and debugging control systems.
• Compliance and safety:
• Ensure all control systems adhere to industry standards, company policies, and safety regulations.
• Design and implement fail-safe systems to ensure machine and operator safety.
• Project management:
• Lead or assist in engineering projects from conception to completion, including budgeting, scheduling, and overseeing contractors.
• Documentation:
• Create and maintain comprehensive documentation for control systems, including electrical schematics, software code, and technical manuals.

Qualifications:

• Education: Bachelor’s degree in Electrical Engineering, Control Systems Engineering, Automation Engineering, or a related field.
• Experience: Minimum 3-5 years of experience in a controls engineering role within a manufacturing environment.
• Skills:
• Proficiency in PLC programming (Allen-Bradley, Siemens, or similar).
• Experience with HMI and SCADA systems.
• Knowledge of industrial networks (Ethernet/IP, Modbus, Profibus).
• Strong understanding of automation systems, robotics, and industrial machinery.
• Solid understanding of electrical systems, including control panel design and wiring.
• Ability to read and create electrical schematics and diagrams.
• Excellent troubleshooting and problem-solving skills.
• Knowledge of safety standards and regulations (NFPA 70E, OSHA, etc.).
• Familiarity with Lean Manufacturing and Six Sigma principles is a plus.

Preferred Qualifications:

• Experience with motion control systems (servo motors, VFDs).
• Familiarity with Industry 4.0 technologies and data analytics.
• Certifications in automation or electrical safety.

Key Competencies:

• Strong analytical and technical skills.
• Ability to work independently and within a team.
• Effective communication and project management skills.
• Detail-oriented with a focus on quality and efficiency.

Physical Requirements:

• Ability to work in a manufacturing environment, including standing, walking, and occasional lifting of up to 50 lbs.
• Willingness to work flexible hours, including weekends or overtime as needed.