Controls Engineer

Controls Engineer

We are seeking a Controls Engineer to design, program, and commission industrial control systems that ensure safe, efficient, and reliable operation of manufacturing and process equipment. The role focuses on PLC and HMI development, systems integration, troubleshooting, and continuous improvement across projects and operational sites. The ideal candidate will collaborate with electrical, mechanical, and process teams to deliver robust control solutions that meet technical and regulatory requirements.

Key Responsibilities

• Design, program, and validate PLC control logic for process and machine automation (Allen-Bradley, Siemens, or similar).
• Develop and maintain HMI/SCADA screens, alarms, and operator interfaces to ensure clear, safe operation.
• Integrate field instrumentation, drives, and smart devices into control systems and verify communication protocols (Ethernet/IP, Modbus, Profibus, etc.).
• Prepare electrical control schematics, I/O lists, wiring diagrams, and control system documentation.
• Lead factory acceptance testing (FAT), site acceptance testing (SAT), commissioning, and startup activities.
• Troubleshoot and resolve control system faults during commissioning and production support, including root cause analysis and corrective actions.
• Work with project managers and cross-functional teams to scope control system requirements, estimate effort, and deliver projects on schedule.
• Implement control strategies that improve process performance, reliability, and safety; support continuous improvement initiatives.
• Ensure designs comply with applicable safety standards, codes, and company procedures; support risk assessments and safety instrumented system requirements.
• Train operations and maintenance personnel on control system functionality and best practices; produce clear as-built documentation and manuals.

Qualifications

• Bachelor’s degree in Electrical Engineering, Control Systems, Mechatronics, or related field (or equivalent experience).
• 3+ years of hands-on experience designing, programming, and commissioning industrial control systems with PLCs and HMIs.
• Proven experience with PLC programming languages (ladder logic, function block, structured text) and with platforms such as Rockwell/Allen-Bradley, Siemens TIA/Step7, or equivalent.
• Experience developing HMI/SCADA applications and alarm management; familiarity with common HMI tools (FactoryTalk, WinCC, Ignition, etc.).
• Strong troubleshooting skills for control hardware, networking, and field instrumentation.
• Knowledge of control system architecture, motor drives, PID control, and industrial communication protocols (Ethernet/IP, Modbus, Profibus, OPC).
• Ability to read and produce electrical schematics, P&IDs, and I/O documentation; experience with control panel design preferred.
• Experience with commissioning, FAT/SAT procedures, and site startups; comfortable working on site and traveling as required.
• Excellent problem-solving, communication, and teamwork skills; ability to work independently and manage multiple tasks.
• Relevant certifications (e.g., Certified Automation Professional, PLC vendor certificates) are a plus.