Job brief
We are seeking a proactive Controls Engineer to lead the design and implementation of advanced automation solutions for our high-capacity production facilities. You will take ownership of the full lifecycle of our control systems—from initial circuit design and panel layouts to final field commissioning and testing. This is an exciting opportunity to leverage your expertise in motion control and industrial networking to modernize our infrastructure and drive significant gains in operational performance. If you are passionate about precision engineering and solving complex integration challenges, we want you on our team.
Key highlights
- Program and troubleshoot complex PLC logic using platforms such as Rockwell Studio 5000, Siemens TIA Portal, or Schneider Unity Pro.
- Design and update electrical schematics, control panel layouts, and P&ID drawings using AutoCAD Electrical to ensure regulatory compliance.
- Lead the commissioning and validation of automated machinery, performing I/O checks, sensor calibration, and motion controller tuning.
- Implement industrial cybersecurity and safety-rated controls according to NFPA 79 and ISO 13849 standards to protect personnel and equipment.
What is a Controls Engineer?
A Controls Engineer is a specialized automation expert responsible for designing, programming, and maintaining the electronic and mechanical systems that drive industrial processes. By integrating hardware like Programmable Logic Controllers (PLCs) with sophisticated Human-Machine Interfaces (HMIs) and SCADA software, a Controls Engineer creates the operational backbone of modern manufacturing environments. Their work is critical to ensuring high-speed production, precision control, and long-term infrastructure reliability across sectors like automotive, energy, and pharmaceuticals.
What does a Controls Engineer do?
On a daily basis, a Controls Engineer programs PLC logic, troubleshoots complex automation loops, and debugs industrial communication networks like Ethernet/IP, Profinet, or Modbus. They spend significant time on the plant floor commissioning equipment, validating PID control loops, and performing safety-rated system integration to meet OSHA or ISO standards. They collaborate closely with mechanical engineers and maintenance technicians to implement upgrades, optimize cycle times, and resolve technical bottlenecks that impact production throughput.
Key responsibilities
- Program and troubleshoot complex PLC logic using platforms such as Rockwell Studio 5000, Siemens TIA Portal, or Schneider Unity Pro.
- Design and update electrical schematics, control panel layouts, and P&ID drawings using AutoCAD Electrical to ensure regulatory compliance.
- Configure and integrate HMI/SCADA interfaces using FactoryTalk View or Ignition to provide real-time operational data to stakeholders.
- Lead the commissioning and validation of automated machinery, performing I/O checks, sensor calibration, and motion controller tuning on the factory floor.
- Implement industrial cybersecurity and safety-rated controls according to NFPA 79 and ISO 13849 standards to protect personnel and equipment.
- Analyze historical production data to identify technical bottlenecks and implement root-cause improvements to machine cycle time and reliability.
- Coordinate with system integrators and electrical contractors to oversee the installation and final acceptance testing of new automation equipment.
- Develop comprehensive technical documentation, including standard operating procedures (SOPs) and maintenance manuals for plant floor personnel.
Requirements and skills
- Bachelor’s degree in Electrical Engineering, Mechatronics, or a related technical discipline with 3+ years of experience in industrial automation.
- Advanced proficiency in PLC programming languages (Ladder Logic, Structured Text, Function Block) and industrial fieldbus communication protocols.
- Proven experience designing electrical control systems and interpretating complex blueprints and electrical schematics according to NEC standards.
- Hands-on expertise configuring Variable Frequency Drives (VFDs), servo drives, and motion control hardware from manufacturers like Allen-Bradley or Yaskawa.
- Strong analytical ability to perform fault diagnosis on electrical circuits, motor control centers, and distributed I/O modules under pressure.
- Demonstrated knowledge of industrial safety protocols including LOTO, machine guarding, and safety-rated PLC programming for risk mitigation.
- Certification or deep working knowledge of SCADA/IIoT platforms such as Ignition, Wonderware, or FactoryTalk for data collection and analysis.
- Ability to communicate complex technical system issues clearly to cross-functional maintenance and production teams to drive consensus on repairs.
FAQs
What does a Controls Engineer do in a manufacturing environment?
A Controls Engineer manages the hardware and software that make machines work automatically. They write code for PLCs (Programmable Logic Controllers), design electrical systems, and troubleshoot automated assembly lines. Their primary goal is to ensure production equipment runs smoothly, safely, and efficiently while minimizing downtime.
What are the essential skills for a Controls Engineer?
Essential skills include advanced PLC programming, proficiency in AutoCAD Electrical for drafting schematics, and the ability to configure industrial networks. Knowledge of safety-rated control systems, motion control (servos/VFDs), and HMI development is also critical. Beyond technical skills, troubleshooting capabilities and a strong understanding of industrial communication protocols like Ethernet/IP are mandatory.
Who does a Controls Engineer collaborate with on a project?
They act as the bridge between the design office and the plant floor. Controls Engineers work closely with mechanical engineers during machine design, maintenance technicians during equipment installation and repairs, and project managers to keep system integration on schedule. They also interact with outside vendors and system integrators to procure and install specialized industrial hardware.
Why is the role of a Controls Engineer important for business success?
Controls Engineers are vital because they directly impact a company’s production capacity and operational costs. By implementing high-efficiency automation and reducing machine failures through robust programming, they enable companies to meet output quotas and maintain strict safety standards. In the era of Industry 4.0, their ability to integrate IIoT data systems provides companies with the actionable insights needed to remain competitive.