Sr. Controls Engineer

Vulcan Elements is manufacturing American rare-earth permanent magnets for a secure, resilient future. With a focus on national security and economic resiliency, we serve critical industries such as defense, aerospace, and automotive powering a high-technology future. Vulcan Elements is building a team of ambitious professionals committed to Mission Focus, Technical Excellence, and Transparency.

As the Sr. Controls Engineer (FAT/CSV) you will lead automation acceptance and commissioning for a massive 1 million square foot manufacturing facility expansion. You will own the automation acceptance thread across a large OEM equipment campaign - authoring standardized FAT/SAT protocols, running the program-wide punch register; writing, modifying, and troubleshooting PLC code from punch-item fixes through commissioning and a share of live controls support.

This is a high-impact, high-ownership role requiring deep technical expertise in industrial automation. Domestic and international travel to OEM facilities up to ~50% during test campaigns.

This role begins in Durham, NC and is expected to move to Benson, NC upon completion of new facility.

• Lead hands‑on programming, debugging, and commissioning of Siemens and Allen Bradley/Rockwell PLCs and HMIs for new and existing automation equipment.
• Develop, modify, and maintain PLC code structures, HMI screens, safety circuits, device mapping, and networking configurations to ensure robust and standardized automation performance across all equipment.
• Execute the scaling-equipment design-review campaign, converting findings into hardened, detailed technical deliverables for OEM vendors.
• Review vendor electrical schematics, controls architectures, and PLC/HMI logic. Own the FAT/SAT campaign: author standardized acceptance protocols, covering PLC logic conformance, HMI/alarm acceptance, interlock validation, and network/security verification. Run the program-wide punch list and coordinate witness assignments.
• as-tested code, configuration baselines, punch closure evidence, and commissioning records.
• Integrate with Quality’s validation system - protocols live in Quality’s framework and carry Quality’s approval; you author the automation content and align with Manufacturing Engineering’s master schedule and process acceptance criteria.
• Drive the integration and commissioning of robotics, vision systems, AGVs, conveyors, and motion control systems—including servos and VFDs—to enable seamless material flow and high reliability production operations.
• Configure and maintain communications between PLCs/HMIs and higher level systems (MES/SCADA). Develop and troubleshoot SCADA tags, transactions, alarming, and data acquisition as required.
• Serve as a senior‑level escalation point for diagnosing complex automation issues involving networks, motion systems, instrumentation, and industrial communication protocols.

Deliverables You Will Develop, Review, or Support

• PLC code architecture, HMI screens, vision inspection programs, tag databases, MES/SCADA transaction lists, network IP lists, password inventories, and system backups. As-tested PLC code baselines, configuration backups, and acceptance evidence packages.
• Controls risk assessments, interlock/guarding logic, and safety rated PFMEA inputs.
• Controls layouts, network topology layouts, station cycle times, sequence diagrams, and automation simulations.
• Electrical schematics, pneumatic drawings, controls panel layouts, and industrial network architecture.
• FAT/SAT protocols, the program punch list, I/O checkout records, and handover packages.

Responsibilities and tasks outlined are not exhaustive and may change as determined by the needs of the business

• Bachelor’s or Master’s degree in electrical engineering, Automation Engineering, Mechatronics, or related field with 7+ years of direct industrial automation and controls engineering experience.
• Strong hands‑on experience programming and commissioning Siemens and Allen Bradley/Rockwell PLCs and HMIs.
• Demonstrated multi‑vendor acceptance campaign management, disciplined change control with the ability to triage punch items to fix in situ or kick back to a…