Controls Engineer II

Position Summary

The Controls Engineer applies advanced engineering principles to design, analyze, test, and optimize industrial control systems within a regulated 24/7 medical device manufacturing environment. This role serves as a technical Subject Matter Expert (SME) for automation and robotics, focusing on the high-performance reliability of Rockwell Automation (Allen-Bradley) platforms. The Controls Engineer supports both new and existing systems, including high-precision Form-Fill-Seal (FFS) and thermoforming equipment, leveraging Lean methodologies to maximize Overall Equipment Effectiveness (OEE) and minimize production scrap.

This position works under general supervision, exercising professional judgment to drive digital transformation and operational excellence.

• Analyze, develop, and evaluate complex control systems; improve existing automated equipment and support the integration of new capital projects.
• Serve as the primary technical SME for PLC development, specializing in Rockwell Studio 5000/RSLogix 5000 environments, including Ladder Logic, Function Blocks, and Add‑On Instructions (AOIs).
• Program and integrate industrial robotics with PLC systems, including safety zones, interlocks, and End‑of‑Arm Tooling (EOAT).
• Manage assigned engineering projects, coordinating vendor activities (FAT/SAT), tracking progress, and ensuring seamless operational handovers.
• Perform advanced troubleshooting and root cause analysis (RCA) on servo‑driven motion control systems (Kinetix, Power Flex) and high‑speed automated lines.
• Develop and maintain critical documentation, including Functional Design Specifications (FDS), I/O lists, and network architecture diagrams.
• Optimize equipment performance through the monitoring of Vorne XL OEE metrics and the tuning of PID loops to reduce changeover times and material waste.
• Implement and support industrial networking protocols, specifically Ether Net/IP and managed switches (Stratix), while providing bonus support for Siemens (TIA Portal) environments.
• Author and update Standard Operating Procedures (SOPs) and technical training tools (One Point Lessons) to enhance site‑wide competency among maintenance and operations teams.
• Collaborate cross‑functionally with IT and Production to manage industrial data systems, including SQL databases, Factory Talk Historian, and MES interfaces.
• Support site‑wide safety and quality compliance, participating in risk assessments, safety validations, and GMP change control standards.
• Provide on‑call technical support as part of a structured rotation to ensure continuous production uptime.

Employees are expected to take reasonable care for their own health and safety and that of others while performing job duties. This includes adherence to Lockout/Tagout (LOTO) procedures and the design of safety‑integrated control circuits.

• Core Technical:
  Mastery of Allen‑Bradley PLC systems (Control Logix, Compact Logix) is required.
• Motion & Drives:
  Proficient in Rockwell Power Flex VFDs and Kinetix servo systems; ability to tune PID loops and configure electronic gearing.
• Robotics:
  Experience in robot‑cell integration and teach pendant programming for FANUC or similar industrial robots.
• Software/Digital:
  Proficiency in AutoCAD Electrical; familiarity with Python, VBA, or SQL for data integration is preferred.
• Industrial Networks:
  Strong understanding of Ether Net/IP architecture and managed switch configuration.
• Operational Excellence:
  Understanding of Lean Six Sigma methodologies and data‑driven process improvement.
• SME Leadership:
  Ability to act as a technical lead, influencing decisions and mentoring peers or technicians.
• Bonus
  
  Skills:
  
  Familiarity with Siemens TIA Portal (S7-1200/1500) and Cognex/Keyence vision systems.

• Bachelor’s degree in Engineering or a related technical discipline.
• 4+ years of related controls or automation engineering experience, preferably in a pharmaceutical or medical device environment.
• Advanced hands‑on experience with Rockwell Automation/Allen‑Bradley software and hardware.
• Travel:
  Ability to support occasional business travel (approximately 10%).
• General…