Senior PLC Controls Engineer Automatic Factory implementation

ARENGY, a Technical Consultancy and Recruitment Services company based in the UAE, is looking for an experienced PLC Controls Engineer to design, program, and commission advanced control systems.

The successful candidate will integrate PLC, Safety PLC, IIoT, Digital Twin, machine vision, and PC-based controls to deliver high-reliability, zero-defect production systems with seamless coordination across robots, and test platforms.

• Design and develop PLC-based control systems for automated assembly lines, robotic cells, test stations, and intralogistics systems, including AMRs, AGVs, and RGVs.
• Develop modular and standardized automation architectures, creating reusable PLC libraries, function blocks, templates, and plug-and-play station concepts for scalable deployment.
• Standardize I/O structures, industrial communication protocols, and system interfaces across machines and production lines.
• Program and configure PLC, HMI, SCADA, and Safety PLC systems, ensuring reliable, scalable, and compliant automation solutions in line with SIL, PL, and ISO 13849 requirements.
• Implement Poka-Yoke and sensor-based quality controls, integrating instrumentation such as LVDTs, load cells, and high-speed digital/analog I/O.
• Develop and optimize 2D/3D machine vision, line-scan, and area-scan inspection systems for guidance, alignment, metrology, and quality control.
• Develop PC-based control and test solutions using National Instruments platforms and LabVIEW for data acquisition, process control, and automated testing.
• Integrate automation systems with robotics, assembly equipment, and testing technologies, including tightening, dispensing, pressing, and welding processes.
• Implement IIoT connectivity and data architectures, enabling real-time monitoring, edge computing, and integration with MES, SCADA, and cloud platforms.
• Support Digital Twin / Process Twin applications and ensure synchronization between virtual models and physical production systems.
• Lead system commissioning, validation, and production ramp-up, including FAT, SAT, and IQ/OQ/PQ activities.
• Establish end-to-end traceability, capturing process parameters, test results, and product genealogy.
• Optimize cycle time, throughput, line balancing, and system availability, ensuring effective synchronization between automation, robots, and material-handling systems.
• Develop diagnostic, fault-recovery, and predictive/preventive maintenance strategies to support reliable lights-out operation.
• Design and validate pneumatic automation systems, including valves, actuators, and air-management components.
• Ensure compliance with safety and ergonomic requirements across manual, hybrid, and automated workstations.
• Lead Root Cause Analysis and continuous improvement initiatives, applying data analytics and Lean methodologies.

• Bachelor's or Master's degree in Electrical, Electronics, Mechatronics, Automation Engineering, or a related discipline.
• 10+ years of experience in PLC programming and industrial automation, with strong hands‑on expertise in platforms such as Siemens, Rockwell, Beckhoff, or equivalent.
• Solid knowledge of machine safety and Safety PLC systems, including safety integration and compliance.
• Proven expertise in industrial sensors and instrumentation, including LVDTs, load cells, and digital/analog I/O systems.
• Strong experience with 2D/3D machine vision, including line-scan and area-scan technologies.
• Hands‑on knowledge of National Instruments hardware and LabVIEW for automated testing, data acquisition, and control applications.
• Familiarity with industrial communication networks and protocols, including OPC UA, PROFINET, Ether Net/IP, and Modbus.
• Proven ability to manage commissioning, troubleshooting, debugging, and production support for complex automation systems.