Process Industrialization Controls Engineer

Job Description Summary

The Controls Engineer plays a key role in developing and supporting the automation systems that keep our operations running safely and efficiently. This position combines hands‑on troubleshooting with system design, programming, and ongoing improvement work. The engineer works closely with operations, maintenance, quality, and other engineering groups to ensure equipment performance meets business needs.

Roles and Responsibilities

• Develop and modify PLC programs for new and existing equipment (Allen‑Bradley, Siemens, GE, Fanuc, etc.).
• Create and update HMI interfaces to improve operator usability and equipment visibility.
• Produce electrical schematics, panel layouts, and related documentation.
• Select appropriate control components, sensors, drives, and instruments for projects and upgrades.

• Develop and support vision inspection applications (Cognex, Keyence, Omron, etc.).
• Configure lighting, lenses, and inspection tools to meet part and process requirements.
• Integrate vision systems with PLCs, robots, and plant networks.
• Troubleshoot inspection issues and refine setups to reduce false rejects and improve performance.
• Maintain documentation for inspection logic, program versions, and acceptance criteria.

• Integrate new equipment into existing production systems while coordinating with mechanical, process, and quality teams.
• Test and validate machine sequences, safety circuits, alarm logic, and error recovery conditions.
• Support commissioning of new lines, modifications, and equipment transfers.
• Support new equipment commissioning, retrofits, and upgrades involving Fanuc and Siemens NC control hardware and software.

• Provide technical support to resolve machine control issues and minimize downtime.
• Perform root‑cause analyses and implement corrective actions that prevent repeat failures.
• Maintain backups and version control for PLC, HMI, and network configurations.

• Evaluate equipment performance and identify opportunities to improve cycle time, reliability, and product quality.
• Support Lean, TPM, or Six Sigma efforts with automation expertise.
• Implement logic changes and hardware upgrades that enhance safety and productivity.

• Develop and maintain plant‑wide standards for automation and electrical controls in alignment with GE Vernova Global industrialization standards.
• Establish consistent guidelines for PLC naming conventions, HMI layout, alarm messaging, and diagnostic structure.
• Define preferred hardware, panel design requirements, wiring practices, and bill‑of‑materials expectations.
• Work with engineering and maintenance teams to ensure standards are understood and followed.
• Keep standards aligned with corporate guidelines and update them as technology or business needs evolve.

• Ensure all control system designs comply with applicable codes and standards (NFPA, IEC, ISO, OSHA).
• Develop, test, and validate machine safety functions such as light curtains, E‑stops, door interlocks, and safety PLC logic.
• Participate in risk assessments and support the implementation of corrective actions.

• Lead and support automation‑related projects from initial concept through installation and start‑up.
• Coordinate with vendors and internal teams to meet project timelines and budget targets.
• Provide training and documentation for maintenance and operations personnel.

Required Qualifications

• Bachelor’s degree in Electrical Engineering, Controls Engineering, Mechatronics, or related discipline.
• Hands‑on experience with PLC programming (ladder, structured text, function block).
• Familiarity with HMI/SCADA development tools.
• Strong understanding of industrial communication networks (Ether Net/IP, Profinet, Modbus, OPC).
• Working knowledge of machine safety requirements and electrical codes.

Desired Characteristics

• Experience in manufacturing or industrial automation environments.
• Exposure to robotics (Fanuc, ABB, KUKA, UR).
• Experience with vision systems beyond basic inspection (pattern recognition, AI‑assisted tools).
• Understanding of MES systems, data…