Controls Engineer

Job Title:

Controls Engineer

Job Description

This role designs, programs, and commissions advanced automation and control systems for complex manufacturing, material handling, and process applications. The Controls Engineer develops PLC and HMI/SCADA solutions on the Allen-Bradley Logix platform, integrates motion, safety, and third-party equipment, and supports full project life cycles from system architecture through startup and documentation. The position offers opportunities to work on diverse automation projects, collaborate with cross-functional teams, and contribute to high-performance industrial systems.

Responsibilities

+ Design, develop, and deploy comprehensive PLC programs using the Allen-Bradley Logix platform, including Studio 5000 and RSLogix 5000.

+ Develop, configure, and maintain HMI and SCADA applications to support operator interfaces and supervisory control.

+ Program and commission high-speed, multi-axis synchronized motion systems using Kinetix servo drives, virtual master axes, electronic gearing, and camming for precision manufacturing operations.

+ Design, program, and optimize complex conveyor and material handling systems, including accumulation conveyors, sortation systems, palletizers, and handoffs with automated guided vehicles (AGVs) or autonomous mobile robots.

+ Implement tracking, merging, diverting, and barcode or RFID scanning logic to ensure seamless product flow through high-throughput logistics and production lines.

+ Design and optimize control strategies for web handling applications, including tension control, winding and unwinding, and registration for continuous weblines.

+ Engineer control algorithms for extrusion processes, ensuring precise temperature regulation, pressure control, and line speed synchronization.

+ Implement complex batch process sequences in alignment with industry standards such as ISA-88.

+ Design, tune, and troubleshoot advanced PID control loops, including cascade loops, ratio control, and feed-forward strategies to minimize disturbances and maximize process stability.

+ Integrate third-party equipment, robotics, instrumentation, and vision systems into the primary control network using industrial communication protocols such as Ether Net/IP, Control Net, and Device Net.

+ Plan and execute rigorous factory acceptance testing (FAT) and site acceptance testing (SAT), including system debugging, troubleshooting, and on-site commissioning.

+ Design and implement hardware and software safety systems using Allen-Bradley Guard Logix controllers and safety-rated components in compliance with relevant safety standards such as ISO and ANSI B11.19.

+ Create and maintain detailed engineering documentation, including functional design specifications, control philosophy documents, I/O lists, cause-and-effect matrices, and fully commented as-built code.

+ Collaborate with cross-functional teams, vendors, and customers to clarify requirements, resolve issues, and ensure successful project delivery.

+ Lead or support projects in high-pressure manufacturing environments, ensuring systems meet performance, reliability, and safety expectations.

Essential Skills

+ Bachelor's degree in Electrical Engineering, Mechanical Engineering, Computer Engineering, or a related technical discipline, or equivalent practical experience.

+ Minimum of 8-10+ years of hands-on controls engineering experience in a manufacturing, machinery builder (OEM), or heavy industrial process environment.

+ Expert-level proficiency with Allen-Bradley hardware and software ecosystems, including Control Logix, Guard Logix, Studio 5000, Panel View Plus, and Factory Talk View SE/ME.

+ Proven experience in PLC programming for Allen-Bradley platforms, including development, troubleshooting, and optimization.

+ Demonstrated mastery of high-speed motion control and multi-axis coordination using Kinetix servo drives and related motion technologies.

+ Direct experience with continuous web handling lines, including tension control, winding and unwinding, and registration control.

+ Experience in batch processing and continuous process industries, including implementation of ISA-88-based batch sequences.

+ Deep theoretical and practical knowledge of PID loop tuning, cascade control, ratio control, and feed-forward compensation.

+ Extensive experience with conveyor systems and material handling automation, including architecture, product tracking, and high-throughput logistics applications.

+ Familiarity with integration to WMS (Warehouse Management Systems) or MES (Manufacturing Execution Systems) for material handling routing.

+ Strong working knowledge of industrial networking architecture, including Ether Net/IP topology, managed switches, VLANs, and device-level ring (DLR) configurations.

+ Excellent troubleshooting capabilities for complex control systems in manufacturing or industrial environments.

+ Strong cross-functional communication skills and the ability to work independently or lead projects in high-pressure settings.…