PLC Controls Engineer Senior - Day Shift

Job Description

Located in the heart of Central Ohio, Illuminate USA is transforming solar panel manufacturing from our cutting-edge facility in Pataskala. As a new standalone joint venture established by two global leaders in renewable energy, we’ve rapidly grown to over 1,500 associates and are now fully operational in our 1.1 million-square-foot factory. Our vision is to establish one of the largest solar panel manufacturing operations in the Western Hemisphere.

This is an exciting time to join Illuminate USA as we continue to grow and innovate. We’re not just building solar panels—we’re building a team of dedicated, passionate associates eager to make a real impact. If you’re looking to be part of a collaborative, people-focused, and forward-thinking workplace, we want to hear from you!

We offer competitive pay, comprehensive benefits, and continuous opportunities for career growth. Come join us on this journey to create a brighter, more sustainable future in the Columbus area.

Illuminate USA is seeking an experienced PLC Controls Engineer to support and improve manufacturing equipment controls systems across the factory. This role is responsible for PLC programming, controls troubleshooting, software version management, machine controls standards, and continuous improvement of automation performance, uptime, and reliability. The ideal candidate brings strong technical depth, disciplined software controls practices, and the ability to work cross-functionally with Equipment, Process, Quality, IT, and OEM/Dispatch partners.

• Maintain, troubleshoot, and improve PLC-controlled manufacturing equipment to meet uptime and throughput targets.
• Develop and support PLC logic updates, interlocks, safety conditions, and machine sequencing to improve stability and eliminate recurring faults.
• Provide hands‑on support for equipment controls issues including communication faults, sensors, actuators, VFDs/servo drives, and industrial networks.
• Lead root cause investigations for controls-related downtime using structured problem solving (5‑Why, 8D, fault tree, etc.).

• Own controls software lifecycle including backup/restore, change control, version tracking, and release management.
• Maintain validated golden copies of PLC programs, HMI projects, and machine configuration files.
• Support factory controls standards including naming conventions, alarms, documentation, and configuration baselines.
• Ensure appropriate documentation of software changes and communicate updates to stakeholders.

• Identify opportunities to improve equipment reliability through automation enhancements, standardization, and reduction of controls-related downtime.
• Support and drive improvements in OEE, scrap reduction, cycle time stability, and equipment recovery procedures.
• Create recovery/playbooks for critical tools to improve shift-level response and reduce time‑to‑recover.

• Partner with OEMs, Dispatch teams, and internal stakeholders to resolve machine controls issues, implement upgrades, and close technical gaps.
• Work alongside Maintenance and Equipment Technicians to improve troubleshooting capability through training and standardized procedures.
• Support commissioning, retrofits, upgrades, and line expansions requiring PLC/HMI integration.

• Bachelor’s degree in Computer Science, Electrical Engineering, Automation Engineering, or equivalent technical discipline
• Minimum 5 years of hands‑on PLC controls engineering experience in a manufacturing environment
• Strong experience with:
• PLC programming and troubleshooting (ladder logic, structured text, etc.)
• HMI/SCADA support and interface troubleshooting
• Industrial networking (Ethernet/IP, Profinet, Modbus, etc.)
• Controls-related documentation and disciplined change management
• Ability to work independently, prioritize production‑impacting issues, and communicate clearly under pressure

• Experience supporting high‑volume manufacturing lines (automation‑intensive environments preferred)
• Exposure to safety systems…