Automation Controls Engineer

We are partnering with a manufacturing client in Sauk Village, Illinois, to identify an experienced Automation/Controls Engineer to join their Maintenance and Engineering team.

This position is responsible for developing, implementing, and managing automation, instrumentation, and control systems supporting extrusion, thermoforming, converting, material handling, and process support equipment. The successful candidate will play a critical role in equipment design, controls integration, system reliability, troubleshooting, project management, and continuous improvement initiatives.

The ideal candidate is a hands-on engineer with strong PLC programming, controls design, and manufacturing experience who can effectively collaborate with maintenance, engineering, production, quality, contractors, and vendors to improve equipment performance, product quality, and operational efficiency.

Key Responsibilities

Automation & Controls

• Troubleshoot PLC, HMI, and VFD hardware and software systems for new and existing equipment.
• Support and program Allen-Bradley, Siemens, B&R, and Yaskawa control platforms.
• Maintain, back up, and manage PLC programs, PC-based control programs, drive programs, HMI applications, and associated firmware.
• Ensure equipment software and firmware remain updated and aligned with current technologies.
• Support the installation, integration, and maintenance of vision systems, including Banner, Keyence, and Cognex.

Engineering & Design

• Design control systems for new and existing machinery, including:
  • Electrical power and controls
  • Programming systems
  • Pneumatic systems
  • Hydraulic systems
  • Mechanical systems
• Develop electrical and mechanical design specifications.
• Create and maintain detailed engineering documentation and schematics.
• Maintain and update electrical schematics, facility power distribution documentation, fire protection schematics, and security system drawings.

Maintenance & Reliability

• Provide technical support to maintenance personnel for production, automation, and facility process equipment.
• Recommend, implement, and support safety improvements and protocols.
• Recommend and implement reliability improvements and preventive maintenance schedules for facility power distribution systems.
• Develop and support predictive and preventive maintenance programs to maximize equipment uptime and efficiency.

Continuous Improvement

• Recommend, implement, and manage improvement projects involving extrusion, thermoforming, automation, and material handling equipment.
• Promote and initiate advanced testing methodologies.
• Improve equipment performance through design enhancements, inspection systems, and software upgrades.
• Support corporate sustainability initiatives and project objectives.

Project Management

• Manage projects from concept through implementation.
• Ensure projects are completed on schedule, within budget, and in accordance with specifications.
• Prepare project appropriations and maintain project documentation.
• Provide regular reports regarding project status, issues, risks, and developments.

Documentation & Reporting

• Prepare operating, maintenance, and troubleshooting manuals for tooling and equipment.
• Maintain complete and accurate project and engineering records.
• Ensure proper documentation of equipment modifications, upgrades, and controls programs.

Collaboration

• Plan and organize daily activities and project team activities to ensure operational responsibilities and project objectives are achieved.
• Work closely with Engineering, Operations, Maintenance, Production, Quality, contractors, consultants, vendors, and customers.
• Foster productive working relationships across departments and external partners.
• Continue developing technical knowledge and skills to maximize effectiveness and support organizational goals.

Required Skills

• Strong understanding of computer programming and software development
• Experience troubleshooting automation and controls systems
• Ability to perform complex system testing and root-cause analysis
• Strong analytical and creative problem-solving skills
• Excellent attention to detail
• Effective written and verbal communication skills
• Ability to work independently and as part of a cross-functional team

Special Qualifications

• Electrical and Control Systems expertise
• Manufacturing Processes and Procedures experience
• Strong written and verbal communication skills
• Ability to utilize precision measuring devices
• 3D Modeling and CAD experience
• Proficiency with Microsoft Office Suite

Education

• Bachelor's Degree in Electrical Engineering or related technical field preferred.
• Equivalent combinations of education, technical training, and work experience will be considered.
• Candidates with a minimum of five (5) years of directly related experience and relevant technical coursework/training are encouraged to apply.

Experience

Preferred experience includes 3-6 years in one or more of the following areas:

• Electrical and Control Systems Engineering
• Automation Engineering
• Engineering Project Management
• Tool Design
• Equipment Design
• Product Design
• Manufacturing Engineering

Work Environment

• Approximately 75% office environment
• Approximately 25% manufacturing floor environment
• Exposure to manufacturing machinery, automation systems, and production noise

Physical Requirements

• Occasionally lift up to 50 pounds
• Hands-on work with tooling and machinery
• Frequent computer use, including keyboard and mouse operation

Why This Opportunity?

This role offers the opportunity to make a significant impact on manufacturing operations by leading automation initiatives, improving equipment reliability, supporting advanced technology implementations, and driving continuous improvement projects within a growing manufacturing environment.

How to Apply

Interested candidates should apply through LinkedIn and submit:

Current Resume
Salary Requirements (Required)
Summary of Relevant Automation/Controls Experience