Controls Engineer

Job Title: Controls Engineer – Automated Storage & Retrieval Systems (ASRS)

Location: Libertyville, IL

Job Description:

About the Role:

We are seeking a highly skilled Controls Engineer to support, maintain, and optimize Shuttle-based ASRS systems for tote and pallet handling (non-Kardex). The role will focus on ensuring high system availability, supporting operations, and delivering continuous improvements in automated warehouse performance. The ideal candidate will have strong expertise in controls engineering, PLC programming, and warehouse automation technologies and experience working in high-volume distribution or manufacturing environments.

Key Responsibilities:

• Provide controls engineering support for Shuttle-based ASRS warehouse systems (for both totes and pallets).
• Troubleshoot and maintain PLCs, SCADA, conveyors, shuttle systems, and other automated material handling equipment.
• Collaborate with operations, maintenance, and IT to ensure smooth integration between ASRS, WCS (Warehouse Control Systems), and WMS (Warehouse Management Systems).
• Perform root cause analysis and implement long-term solutions for recurring controls/system issues.
• Support system commissioning, testing, and modifications of ASRS equipment and controls.
• Develop, review, and maintain control system documentation, electrical schematics, and programming logic.
• Ensure compliance with safety, regulatory, and operational standards.
• Partner with OEMs, vendors, and internal teams to resolve technical challenges and optimize system performance.
• Support future upgrades, retrofits, and expansions of ASRS and automation systems.

Qualifications & Skills:

• Bachelor’s degree in Electrical Engineering, Mechatronics, Controls Engineering, or a related field (or equivalent experience).
• Proven experience with ASRS shuttle systems (not Kardex), conveyors, and pallet/tote handling automation.
• Hands-on experience with PLC programming (Siemens, Allen-Bradley, or equivalent).
• Knowledge of industrial networks and communication protocols (Profinet, EtherNet/IP, OPC, etc.).
• Experience working with WCS/WMS integration.
• Strong troubleshooting skills in high-speed automated environments.
• Familiarity with safety systems (E-stops, interlocks, functional safety standards).
• Ability to work in a fast-paced, 24/7 operations environment (with on-call or shift support as needed).
• Strong communication and cross-functional collaboration skills.

Preferred Experience:

• Previous experience in large-scale automated distribution centers or manufacturing facilities.
• Exposure to Flex ASRS solutions or comparable shuttle/pallet-handling systems.
• Knowledge of data collection, reporting, and system performance analytics.
• ASRS Warehouse management
• They are looking for more senior candidates, more of SME level.
• Knowledge of multiple ASRS warehouse management systems
• 10-15 years experience.