Controls Engineer

Job Description

The Controls Engineer designs, programs, and supports automated machinery by developing robust PLC and HMI solutions, integrating robotics and vision systems, and ensuring reliable, safe, and efficient machine operation throughout the full automation lifecycle. This role combines hands-on programming, system integration, testing, and field support, with a strong focus on clear documentation, collaboration with build teams, and delivering high-quality turnkey automation systems to customers.

Responsibilities

+ Create, update, and troubleshoot PLC ladder logic to meet customer requirements and internal engineering standards.

+ Design, configure, and refine HMI screens to provide intuitive, user-friendly interfaces for machine operators and maintenance personnel.

+ Work with technologies such as cameras, robots, sensors, and vision systems to ensure all components of an automated machine operate smoothly together.

+ Test machine sequences thoroughly and verify that physical components, including switches, actuators, and cylinders, are wired correctly and function as intended prior to deployment.

+ Serve as the primary controls programmer on small to mid-sized automation projects, taking ownership of control system design, implementation, and commissioning.

+ Support project timelines by contributing to schedules, tracking milestones, and coordinating with mechanical and electrical teams during the machine build process.

+ Maintain clear, organized project documentation, including wire lists, calibration data, technical specifications, and configuration details for controls hardware and software.

+ Review and contribute to machine manuals so that customers receive accurate, complete, and easy-to-follow operating and maintenance documentation.

+ Support electrical and mechanical technicians during machine builds and debug by answering technical questions, assisting with wiring checks, and troubleshooting control issues.

+ Debug control systems and optimize machine performance, making program and configuration adjustments to improve reliability, throughput, and safety.

+ Participate in and support validation activities such as Installation Qualification (IQ), Operational Qualification (OQ), and Performance Qualification (PQ), particularly for regulated or medical device applications.

+ Assist with Factory Acceptance Testing (FAT) and Site Acceptance Testing (SAT), ensuring that machines meet performance, quality, and compliance requirements before and after installation.

+ Travel to customer sites to install, commission, and update machines, and provide occasional emergency service support, including troubleshooting and implementing corrective actions in the field.

+ Collaborate with cross-functional teams to support the full turnkey automation lifecycle, from initial design and system architecture through programming, testing, installation, and ongoing service.

+ Other duties as assigned.

Qualifications

+ Bachelor's degree in Electrical Engineering, Mechatronics, or a related field, or equivalent hands-on experience;
Bachelor's degree preferred.

+ Minimum of 3-5 years of hands-on experience in controls programming or industrial automation.

+ Strong PLC programming skills with proficiency in ladder logic; experience with structured text or function block programming is a plus.

+

Experience with HMI and SCADA development, including designing and implementing operator interfaces.

+ Experience working with automated and electrical systems that include robots, vision systems, sensors, drives, AC/DC circuits, PNP/NPN devices, safety circuits, and motion control (servo and stepper systems).

+ Ability to read and interpret electrical schematics, wiring diagrams, and technical documentation.

+ Basic understanding of pneumatic systems and electro-mechanical assemblies and how they integrate with control systems.

+ Ability to independently troubleshoot complex control systems, including in customer-facing and field service environments.

+ Experience supporting validation activities such as IQ, OQ, and PQ, particularly in regulated or medical device settings.

+ Ability to support Factory Acceptance Testing (FAT) and…