Controls Automation Engineer

Controls & Automation Engineer

POSITION SUMMARY

We are seeking a hands-on Controls & Automation Engineer to progressively improve and expand automation throughout our manufacturing facility.

Restore and Stabilize. Assess and restore existing equipment to dependable operation by correcting controls issues, recovering failed or bypassed automation, eliminating unnecessary manual workarounds, supporting production downtime, and bringing backups and documentation to a consistent standard.

Modernize and Upgrade. Improve existing equipment through stronger PLC logic, intuitive HMIs, better diagnostics, machine vision, robotics, and appropriate safety systems. Enhancements should simplify operation, improve reliability, and integrate cleanly with the surrounding process.

Design and Automate. Redesign or replace equipment when existing systems can no longer meet safety, reliability, maintainability, or production needs. Develop new automated cells from specification through programming, integration, commissioning, documentation, training, and production handoff using practical company standards.

CORE RESPONSIBILITIES

· Diagnose PLC, HMI, robot, and vision faults and return equipment to reliable operation.

· Correct controls bugs, bypassed functions, recurring failures, and unnecessary manual processes.

· Program PLC/HMI systems using ladder logic, structured text, function blocks, or other appropriate methods.

· Develop operating modes, sequences, permissives, interlocks, alarms, diagnostics, fault recovery, and safe-restart logic.

· Select and commission sensors, drives, HMIs, machine vision, robots/cobots, and custom interfaces.

· Configure cameras, lighting, triggers, calibration, recipes, tolerances, and pass/fail criteria.

· Add scripts, APIs, or custom GUIs when standard vendor capabilities are insufficient.

· Program and integrate robots/cobots for welding, press tending, material handling, fixture verification, and inspection.

· Establish reliable communications and handshakes across control, process, and safety systems.

· Perform risk assessments and design and validate safety for production, setup, cleaning, jam clearing, maintenance, and foreseeable operator actions.

· Evaluate upgrade-versus-replace options based on safety, reliability, maintainability, production needs, and cost.

· Develop new automated cells from concept and specification through programming, integration, commissioning, and production handoff.

· Coordinate vendors and integrators and validate system performance under production conditions.

· Establish standards for controls hardware, programming, HMI design, alarms, naming, backups, documentation, and change control.

· Maintain source files, schematics, redlines, and backups; train operators and maintenance personnel.

REQUIRED QUALIFICATIONS

· Bachelor's degree in Electrical Engineering, Controls, Automation, Mechatronics, Mechanical Engineering, or a related field, plus five years of relevant industrial experience.

· Strong PLC/HMI programming, commissioning, and plant-floor troubleshooting skills across commonly used industrial platforms.

· Hands-on integration experience with robots/cobots, machine vision, safety circuits, drives, sensors, industrial communications, electrical controls, and pneumatics.

· Ability to develop custom logic or interfaces in at least one programming or scripting language, perform root-cause analysis, and communicate effectively across functions.

· Preferred experience with major robotic brands like ABB, FANUC, Yaskawa, Motoman, OTC, or Universal Robots; PLC platforms such as Rockwell Automation/Allen-Bradley, Siemens, Mitsubishi, or AutomationDirect; Vision systems such as KEYENCE, Cognex, or SICK.

· Experience with welding, brake presses, conveyors, paint/coating, motion, fixtures, or material handling.

· Fully onsite in South Carolina, with occasional after-hours/weekend support and the ability to lift, climb, bend, and work safely around automated equipment.

Pay: $85,000.00 - $95,000.00 per year

Benefits:

• 401(k) matching
• Dental insurance
• Flexible spending account
• Health insurance
• Health savings account
• Life insurance
• Paid time off
• Vision insurance

Ability to Commute:

• Lugoff, SC 29078 (Preferred)

Work Location: In person

Salary : $85,000 - $95,000