Sr Controls Engineer ~ Allen-Bradley PLC-

Sr Controls Engineer

Onsite.

Sr Controls Engineer supports manufacturing data integration and reporting within a clean‑room medical device manufacturing environment. The role focuses on connecting PLC and non‑PLC based production equipment to an Ignition server and underlying databases to reliably capture machine and process data. This data drives site‑wide OEE, equipment performance, and operational dashboards that improve visibility and decision‑making. The engineer also supports Power BI dashboard development and maintenance.

• Connect PLC/Rockwell‑based and other production equipment to the Ignition platform and related databases.
• Troubleshoot communication, connectivity, and data flow issues between manufacturing equipment, Ignition, and reporting tools.
• Configure, validate, and maintain tags, data points, and data structures used for operational reporting and analytics.
• Support development and enhancement of site‑wide OEE, equipment performance, and manufacturing dashboards.
• Assist with Power BI reports that pull data from Ignition and related sources, including publishing, maintenance, and scheduled refresh.
• Partner with engineering, operations, and other stakeholders to translate manufacturing data and reporting needs into practical dashboard solutions.
• Help ensure production data is accurate, consistent, and accessible to support performance monitoring and continuous improvement in a regulated manufacturing setting.
• Modify existing Allen‑Bradley PLC‑based manufacturing test equipment to support data integration with the Ignition platform.
• Design and implement data communication architectures within an Industry 4.0 environment.
• Follow best practices for the validation and verification of Non‑Product Software (NPS).
• Contribute to software development for systems for data transmission, storage, and visualization.
• Define and create techniques for testing performance and quality in data transmission architectures.
• Contribute to code and design reviews of NPS.
• Develop and execute engineering verification and validation protocols for software‑controlled systems.
• Stay abreast of advances in latest technologies related to SCADA systems and streaming data architectures.
• Perform any other duties and responsibilities as assigned.

• Industrial automation integration
• Strong experience connecting PLC based manufacturing equipment, especially Rockwell/Allen‑Bradley systems, to SCADA/MES/data platforms such as Ignition, including PLC communications, tag structures, OPC UA, industrial networking, and real‑time data acquisition.
• Hands‑on expertise with the Ignition platform for device connectivity, tag management, database integration, scripting, and dashboard/data pipeline development.
• Advanced capability in Power BI and SQL/database‑connected reporting, including building, publishing, and maintaining automated dashboards that refresh from manufacturing data sources such as Ignition.
• Ability to model operational data for actionable KPIs.

• Expertise in Allen‑Bradley PLC software development.
• Experience with the Ignition platform from Industrial Automation.
• Demonstrated ability in the design, development and verification of software systems.
• Demonstrated ability to work in cross‑functional teams.
• Demonstrated ability to work with embedded systems.
• Strong interpersonal skills.
• Strong written and verbal communication skills.
• Strong attention to detail.
• Proficiency with Microsoft Office tools, including Excel, Word, PowerPoint and Visio.

• Medical Device experience, QSR experience, and familiarity with change control processes in a regulated environment.
• Experience with the concepts of Digital Factory, IIoT, and Industry 4.0.
• Experience with the validation of software in a regulated industry.
• Experience with the DeviceWISE platform from Tellit.
• Experience with the MQTT protocol.
• Experience with Python programming.
• Experience with PLC programming and the OPC‑UA protocol.
• Experience with the test and validation of visual display interfaces.
• Experience with version control systems.
• Experience with HiveMQ.
• SQL experience.
• Demonstrated experience applying principles of Statistical Process Control (SPC) and/or Operational Equipment Effectiveness (OEE).

• Bachelor of Science in an engineering field or computer science.
• 3–5 years of relevant experience.