Maintenance and Controls Engineer

Executive Search Consultant - Electrical Engineering & Automation

Position Summary

We are seeking a Maintenance and Controls Engineer to join our team. This hybrid role combines hands‑on maintenance expertise with advanced automation and controls engineering. The ideal candidate will lead automation initiatives, support maintenance teams, and ensure the reliability, efficiency, and continuous improvement of plant equipment and systems.

• Provide hands‑on support to maintenance technicians for diagnosing and repairing mechanical, electrical, and control system issues.
• Troubleshoot and resolve complex problems involving PLCs, robotics, hydraulics, pneumatics, and electrical systems.
• Ensure maintenance teams have the tools, training, and resources needed for efficient operations.
• Design, develop, and implement automation systems including robotics, PLCs, HMIs, and machine vision technologies.
• Develop and maintain an automation roadmap aligned with operational goals.
• Evaluate and select automation hardware/software; conduct feasibility studies and ROI analyses.
• Develop and monitor preventive and predictive maintenance programs using CMMS and data analytics tools.
• Lead efforts to improve equipment reliability, reduce downtime, and address warranty issues.
• Support the use of predictive maintenance technologies to enhance uptime.
• Lead installation, commissioning and upgrades of new and existing equipment.
• Prepare capital equipment requests and manage project timelines and budgets.
• Coordinate with vendors and travel for equipment inspections, runoffs, and training.
• Participate in daily production meetings and equipment walk‑arounds.
• Collaborate with cross‑functional teams to identify automation opportunities and drive process improvements.
• Align automation strategies with business goals using data‑driven insights.
• Develop and maintain SOPs, training materials, and technical documentation.
• Coordinate off‑site and on‑site training for maintenance technicians.
• Participate in hiring and onboarding processes for technical staff.

• Proficiency in PLC programming (e.g., Allen‑Bradley, Siemens), robotics, and control systems.
• Strong project management and vendor coordination skills.
• Excellent problem‑solving, communication, and collaboration abilities.
• Willingness to travel for equipment support and training coordination.
• Experience with injection molding, extrusion, or thermoforming equipment.
• Familiarity with machine vision systems and advanced automation technologies.
• Knowledge of predictive maintenance tools, data analytics platforms, and regulatory compliance standards.

• Bachelor's degree in Electrical, Mechanical, or Automation Engineering (or related field).
• 5+ years of experience in industrial maintenance and automation, preferably in plastics or high‑volume manufacturing.

Base pay range

$/yr – $/yr