Controls & Automation Engineer

Company Description SARACA is a global engineering R&D services company serving 25 Fortune 500 customers across industries such as MedTech, Aerospace, Rail, Automotive, Semiconductor, Defense, and Farm equipment. The company is ISO 13485 certified and has extensive experience in designing and developing next-generation medical devices, including embedded software, UI/UX, mechanical systems, and product testing. SARACA offers unique expertise in IEC 62304, EU MDR, Clinical Evaluation Reports, Performance Evaluation Reports, and scientific writing for MedTech. With a technically strong team of 400 engineers and management consultants, SARACA delivers results on onsite and offsite projects worldwide while solving complex business challenges. As an equal-opportunity employer, SARACA fosters a culture of innovation, continuous learning, and customer-focused growth.

Position: Controls & Automation Engineer

Location: Hopkinsville, KY or Clarksville, TN (Onsite)

Start Date: Immediate

Background Check: Mandatory

Request ID: B7T6CX

We are looking for an experienced Controls & Automation Engineer with strong hands-on expertise in Rockwell Automation/Allen-Bradley PLCs, FactoryTalk, PTC Kepware, industrial networking, and OT connectivity.

The engineer will be responsible for developing, commissioning, troubleshooting, and maintaining industrial automation systems while enabling reliable communication between shop-floor equipment, PLCs, SCADA, MES, historians, and enterprise systems.

• Design, program, test, troubleshoot, and commission Allen-Bradley PLC systems using Studio 5000, RSLogix 5000, and RSLogix 500.
• Develop and maintain control logic for ControlLogix, CompactLogix, and GuardLogix platforms.
• Develop and configure FactoryTalk View ME/SE HMI applications, alarms, trends, diagnostics, and operator interfaces.
• Integrate and troubleshoot PowerFlex VFDs, Kinetix servo drives, and motion-control systems.
• Perform system commissioning, equipment start-up, I/O checkout, loop checks, functional testing, and troubleshooting.
• Configure and maintain PTC Kepware/KEPServerEX for OT data acquisition and connectivity.
• Configure Kepware channels, devices, tags, drivers, scan rates, addressing, and communication parameters.
• Implement and troubleshoot OPC DA, OPC UA, MQTT, REST, and IoT Gateway connectivity.
• Integrate shop-floor devices and PLCs with SCADA, MES, historians, databases, and cloud/enterprise systems.
• Configure and troubleshoot industrial protocols including EtherNet/IP, CIP, Modbus TCP/RTU, and PROFINET.
• Support industrial networks, managed switches, VLANs, NAT, routing, and OT network diagnostics.
• Collaborate with IT/OT teams to develop reliable, secure, and scalable industrial automation architectures.
• Perform root-cause analysis of PLC, HMI, instrumentation, hardware, and communication failures.
• Provide hands-on technical support to maintenance and production teams to minimize equipment downtime.
• Develop and maintain I/O lists, electrical schematics, P&IDs, control narratives, network diagrams, FDS, and commissioning documentation.
• Support automation upgrades, equipment modifications, system migrations, and continuous improvement initiatives.
• Apply machine and functional safety principles aligned with ISO 13849, IEC 62061, and IEC 61508.
• Follow OT cybersecurity best practices, including ISA/IEC 62443, network segmentation, access control, certificates, backups, and system hardening.
• Participate in design reviews, FAT/SAT, risk assessments, safety reviews, and system validation activities.

• Strong industrial controls and automation engineering experience.
• Hands-on Rockwell Automation / Allen-Bradley PLC programming experience.
• Studio 5000 / RSLogix 5000 / RSLogix 500.
• ControlLogix, CompactLogix, and/or GuardLogix.
• FactoryTalk View ME/SE.
• PTC Kepware / KEPServerEX.
• OPC DA/UA, MQTT, REST, and industrial IoT connectivity.
• EtherNet/IP, CIP, Modbus TCP/RTU, and/or PROFINET.
• Industrial networking and OT architecture.
• PowerFlex VFDs and/or Kinetix motion systems.
• PLC/HMI/SCADA commissioning and troubleshooting.
• Ability to read electrical schematics, P&IDs, and I/O documentation.
• Strong root-cause analysis and problem-solving skills.
• Understanding of machine safety and OT cybersecurity principles.
• Excellent communication and documentation skills.
• Bachelor's degree in Electrical Engineering, Controls Engineering, Automation, Mechatronics, or a related field is preferred.

The ideal candidate is a hands-on Controls & Automation Engineer with strong Rockwell PLC programming experience combined with Kepware/OT connectivity expertise. Candidates who have worked in manufacturing environments and have experience integrating PLCs and shop-floor equipment with SCADA, MES, historians, or enterprise systems will be highly relevant.

• If you are interested, please share your updated resume, contact details, current location, work authorization, and availability.