Controls System Engineer

Controls Engineer – High-Speed Automation & Manufacturing

We are seeking a Controls System Engineer to design, develop, and support advanced automation systems in a high-speed manufacturing environment. This role is responsible for ensuring reliable machine control, optimizing system performance, and integrating cutting‑edge automation technologies to support production goals.

• Develop, program, and support controls systems for high-speed automated assembly equipment
• Troubleshoot PLCs, HMIs, motion control systems, and industrial networks to minimize downtime
• Support commissioning, startup, and validation of new automation equipment
• Optimize machine performance for cycle time, reliability, and quality

• Support controls integration for automated material handling systems including robotics, AMRs, AGVs, and conveyor systems
• Develop and maintain logic for movement, storage, and retrieval of totes, pallets, and components
• Ensure seamless communication between equipment and warehouse/production control systems

• Configure, program, and support high-speed vision inspection systems for part quality verification
• Integrate vision systems with PLCs and production equipment
• Troubleshoot vision-related defects and improve inspection performance

• Lead and support improvements using:
  • Lean Manufacturing principles
  • Six Sigma methodologies
  • PDCA (Plan-Do-Check-Act)
  • RCA (Root Cause Analysis)
• Analyze system performance data to identify issues and implement corrective actions
• Drive reliability improvements and reduce downtime events

• Work closely with Mechanical, Manufacturing, Quality, and Maintenance teams
• Partner with system integrators, OEMs, and suppliers for controls development and support
• Provide technical training and support to operations and maintenance personnel

• Bachelor’s degree in Electrical Engineering, Controls Engineering, or related field
• 8 years minimum experience with PLC programming (Rockwell, Siemens, or equivalent)
• Experience with HMIs, motion control, and industrial communication protocols
• Ability to troubleshoot complex automation and control systems
• Strong analytical and problem‑solving skills
• Excellent communication and teamwork abilities

• Experience supporting high-speed automation environments (300+ parts per minute preferred)
• Medical device manufacturing experience strongly preferred
• Experience with:
  • Robotics and automated material handling systems (AMR, AGV)
  • High-speed vision systems (Cognex, Keyence, etc.)
• Proficiency in Lean and Six Sigma methodologies
• Familiarity with MES systems and data integration
• Experience with safety systems and machine safety standards

• Strong troubleshooting and diagnostic skills
• Continuous improvement mindset
• Ability to work in fast‑paced, high‑volume environments
• Hands‑on, results‑driven approach
• Strong collaboration and communication skills

• Combination of office and manufacturing floor
• Hands‑on interaction with automation equipment and controls systems
• Occasional travel for equipment integration and supplier support

• Reports to:
  
  Engineering Manager
• Works closely with:
  Mechanical Engineering, Manufacturing, Quality, Maintenance, and Automation teams