Sr. Controls Engineer - FAT​/CVS & Commissioning

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 alargeOEM 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 technicalexpertisein industrial automation.

Domestic and international travel to OEM facilities up to ~50% during testcampaigns.

• PLC Programming & Commissioning:Lead hands-on programming, debugging, and commissioning of Siemens andAllen
  
  Bradley/Rockwell PLCs and HMIs for new and existing automation equipment.
• Controls Integration & Architecture:Develop,modify,andmaintainPLC code structures, HMI screens, safety circuits, device mapping, and networking configurations to ensure robust and standardized automation performance across all equipment.
• Design Reviews:Execute the scaling-equipment design-review campaign, converting findings into hardened, detailed technical deliverables for OEM vendors.
• Vendor Technical Support & FATs: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.
• Turnover & Baselines:Build controls turnover packages: as-tested code, configuration baselines, punch closure evidence, and commissioning records.
• Validation Interface: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.
• Advanced Automation & System Integration:Support the integration and commissioning of robotics, vision systems, AGVs, conveyors, and motion control systems—including servos and VFDs—to enable seamless material flow andhigh reliabilityproduction operations.
• SCADA/MES Connectivity:Configure andmaintaincommunications between PLCs/HMIs andhigherlevelsystems (MES/SCADA). Develop and troubleshootSCADA tags, transactions, alarming, and data acquisition as required.
• Troubleshooting & Technical Escalation:Serve as a senior-level escalation point for diagnosing complex automation issues involving networks, motion systems, instrumentation, and industrial communication protocols.

• Controls & IT: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.
• Risk & Safety:Controls risk assessments, interlock/guarding logic, andsafetyratedPFMEA inputs.
• Process Design:Controls layouts, network topology layouts, station cycle times, sequence diagrams, and automation simulations.
• Engineering Diagrams:Electrical schematics, pneumatic drawings, controls panel layouts, and industrial network architecture.
• Acceptance & Commissioning:FAT/SAT protocols, the programpunchlist, 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 Masters degree in electrical engineering, Automation Engineering, Mechatronics, or related field with5+years of direct industrial automation and controls engineering experience.
• Strong hands on…