Principal Controls Engineer

Serve as the principal technical authority for PLC, HMI, industrial networking, and data integration platforms across multiple manufacturing plants
Define, maintain, and enforce enterprise-wide standards for control system architecture, programming practices, HMI design, and documentation
Evaluate and approve automation platforms, system designs, and technology roadmaps
Lead controls scope for capital projects, equipment installations, and major process upgrades from concept through commissioning and handover
Develop functional specifications, control philosophies, network architecture, and system layouts for complex manufacturing systems
Provide technical leadership during commissioning, startup, and production ramp-up
Write, debug, and modify PLC code to optimize production efficiency and quality
Create HMI applications for monitoring and controlling machinery
Oversee development, review, and optimization of PLC programs using Allen-Bradley and Siemens platforms
Establish structured programming methodologies and define HMI standards
Architect and support data collection systems, historians, and integration with manufacturing and business systems
Support OEE, downtime analysis, quality metrics, and performance monitoring
Integrate control systems with manufacturing equipment and systems
Act as the highest-level escalation point for complex controls and automation issues
Lead root cause analysis and implement permanent corrective actions
Drive reliability improvements through redesign, standardization, and failure prevention
Maintain comprehensive control system documentation
Ensure compliance with safety standards, regulatory requirements, and corporate policies
Support machine safety initiatives, risk assessments, and validation activities
Mentor controls engineers and technicians through coaching, design reviews, and knowledge sharing
Provide technical oversight for system integrators and OEMs
Identify and implement automation-driven improvements to throughput, quality, uptime, and operating cost
Support long-term automation strategy and technology roadmaps
Drive standardization and replication of best practices across facilities

Requirements

• Bachelor of Science in Electrical Engineering, Controls Engineering, or a related technical discipline (or equivalent experience)
• 10+ years of experience designing, implementing, and supporting industrial automation systems in a manufacturing environment
• Extensive experience with Allen-Bradley and Siemens PLC platforms
• Strong expertise in HMI development, industrial networking, and control system architecture
• Working knowledge of electrical schematics, motor controls, VFDs, and industrial communication protocols
• Demonstrated ability to lead technical decisions, influence stakeholders, and mentor less experienced engineers
• Strong problem-solving skills with the ability to diagnose complex system-level issues
• Excellent communication skills and ability to collaborate across engineering, manufacturing, maintenance, and IT functions
• Certification in PLC programming or industrial automation
• Experience supporting high-speed, high-volume manufacturing operations, preferably in the flooring or building products industry
• Multi-site manufacturing support experience
• Experience with data historians, manufacturing analytics, MES/MOM systems, or digital transformation initiatives
• Formal training or certification in PLCs, industrial automation, or machine safety
• Exposure to Lean Manufacturing, TPM, or continuous improvement frameworks applied to automation systems

Core Competencies

Demonstrates expertise in PLC and HMI development, industrial networking, and control system architecture, with a strong focus on optimizing manufacturing processes and ensuring compliance with safety standards. Proven ability to lead technical projects, mentor engineers, and implement automation-driven improvements across multiple manufacturing sites.

Highest-signal resume keywords

• PLC Programming
• HMI Development
• Industrial Networking
• Control System Architecture
• Automation Strategy

ATS Optimization Keywords

Hard Skills

• Allen-Bradley PLC
• Siemens PLC
• Data Integration
• Control Philosophy Development
• Network Architecture
• Functional Specification Development
• Electrical Schematics
• Motor Controls
• VFDs
• Industrial Communication Protocols

Soft Skills

• Technical Leadership
• Problem-Solving
• Communication
• Collaboration
• Mentoring

Certifications & Qualifications

• PLC Programming Certification
• Industrial Automation Certification
• Machine Safety Certification

Industry Keywords

• Manufacturing Environment
• High-Speed Manufacturing
• High-Volume Manufacturing
• Lean Manufacturing
• Continuous Improvement

Tools & Technologies

• Data Historians
• Manufacturing Analytics
• MES/MOM Systems
• Digital Transformation Initiatives