The Controls Engineer and PLC Specialist is responsible for supporting, maintaining, and enhancing our production and facilities equipment through advanced electrical and PLC troubleshooting, programming, and controls project management. This position will be equally responsible for working on the plant floor with operations staff and collaborating with engineering/management teams on the upgrades and new installations of equipment to improve manufacturing processes.

Principle Accountabilities:

• Analyze current manufacturing processes to identify inefficiencies and recommend automation opportunities.
• Perform regular maintenance, troubleshooting, and upgrades on automated equipment to minimize downtime.
• Conduct system testing and validation to ensure reliability, accuracy, and safety.
• Collaborate with cross-functional teams, including design, production, and quality assurance, to ensure automation aligns with business goals.
• Stay updated on emerging technologies, trends, and best practices in manufacturing automation.
• Ensure compliance with industry standards, safety regulations, and company policies.

• Troubleshooting & Maintenance
  • Diagnose and resolve complex electrical and PLC control issues on production equipment including servo motion and SIL3 safety systems.
  • Provide mechanical troubleshooting support when required to minimize downtime.
  • Utilize electrical schematics to aid in circuit tracing and diagnostics.
• Programming & Controls
  • Write, modify, and optimize PLC programs for maximum equipment performance and safety.
  • Develop new PLC programs from scratch for new machinery or system integrations.
  • Manage PLC program version control and maintain secure access for 50 users.
  • Create and modify electrical schematics for new and existing systems.
• Upgrades & Projects
  • Plan and execute controls-related projects, including upgrades to existing systems and integration of new equipment.
  • Develop and maintain project cost estimates and budgets
  • Review and approve controls designs for new equipment installations to ensure compliance with facility standards.
  • Lead or support PLC and controls upgrades primarily using Rockwell Automation products.
• Software & Licensing
  • Manage and maintain Rockwell Automation software licenses to ensure access to all hardware and firmware versions in the facility.
• Collaboration & Communication
  • Work closely with operations and production teams to understand needs, communicate solutions, and provide training as needed.
  • Partner with maintenance and engineering teams on equipment improvement initiatives.
  • Develop and document Standard Operating Procedures (SOPs) for automated systems and processes.

Behavioral Competencies:

• Builds Trust - Interacts with others in a way that gives them confidence in one’s intentions and those of the organization.
• Initiates Action – Takes prompt action to accomplish objectives; takes action to achieve goals beyond what is required; is proactive.
• Adaptability – Maintains effectiveness when experiencing major changes in work tasks or the work environment; adjusts effectively to work within new work structures, processes, requirements or cultures.
• Build Partnerships – Identifies opportunities and takes action to build strategic relationships between one’s area and other areas, teams, departments, units, or organizations to help achieve business goal.
• Strategic Decision Making – Obtains information and identifies key issues and relationships relevant to achieving a long range goal or visions; commits to a course of action to accomplish a long-range goal or vision after developing
• Contributes to Team Success – Actively participates as a member of a team to move the team toward the completion of goals.

PHYSICAL DEMANDS

Work requires some physical strain such as long periods of standing, bending, climbing and lifting overhead.

WORK ENVIRONMENT

Working around power equipment, slippery floors and dusty areas.  Very hot conditions in some areas during summer season.  Protective clothing such as uniform, gloves, safety glasses and slip resistant shoes are required.

Salary Range - $75,000 - $100,000

• Knowledge/Skills:

• Bachelor’s degree in Electrical Engineering, Controls Engineering, Mechatronics, or related technical field.  An Associate’s degree in Industrial Controls, Automation Technology, or similar may be accepted with significant relevant experience.
• Professional certifications such as Rockwell Automation Certified Programmer, ISA Certified Automation Professional (CAP), or equivalent are a strong plus.
• 5 years of experience in industrial automation, preferably in food manufacturing or a high-speed packaging environment.
• Engineering Technology (ET) and Electronics Engineering Technology (EET) experience strongly preferred.
• Proficiency in programming and configuring PLCs, robotic systems, and industrial control systems.
• Strong expertise with Rockwell Automation/Allen-Bradley PLCs, HMIs, and related software.
• Hands-on experience with electrical troubleshooting and mechanical systems including pneumatics and motorized equipment.
• Experience with AutoCAD Electrical JIC/NFPA drawings.
• Proficient in project planning and execution of electrical/controls upgrades.
• Strong organizational skills to manage program version control and user access control systems.
• Comprehensive understanding of machine guarding techniques and functional safety (SIL/PL)
• Excellent communication and interpersonal skills for collaboration with production staff and leadership.
• Strong knowledge of manufacturing processes and workflows.
• Problem-solving skills and the ability to troubleshoot automation-related issues.
• Excellent communication skills and ability to work collaboratively across teams.
• Experience in Food Manufacturing environment preferred.

Experience:

• 5 years of experience in industrial automation, preferably in food manufacturing or a high-speed packaging environment.
• Engineering Technology (ET) and Electronics Engineering Technology (EET) experience strongly preferred.

PHYSICAL DEMANDS

Work requires some physical strain such as long periods of standing, bending, climbing and lifting overhead.

Salary : $80,000 - $110,000