Senior Controls & Automation Engineer

Title: Senior Automation & Controls Engineers

Location: Louisville, KY

Status of Hire: Direct Placement

Industry: Manufacturing, Metal Fabrication

As the Senior Controls & Automation Engineer you'll work closely with operations, maintenance, engineering, and leadership teams to ensure automation systems perform reliably and efficiently, helping the plant operate safely, productively, and with minimal downtime. Reporting to the Electrical Engineering Manager, you'll serve as a key technical resource for the facility, supporting day-to-day manufacturing operations, improving automation system performance, and driving initiatives that enhance reliability, productivity, and operational excellence.

Responsibilities

Deliver Performance

• Take the lead in optimizing critical automation technologies, ensuring the reliability and performance of PLCs, HMIs, drives, industrial networks, and control systems that are critical to plant operations
• Partner closely with operations and maintenance teams to improve equipment reliability, process stability, and overall plant performance.
• Monitor process performance and identify opportunities to increase uptime, efficiency, quality, and throughput.
• Participate in root cause analyses and implement sustainable corrective actions to prevent recurring issues.
• Support startup activities, equipment modifications, and system improvements to ensure seamless operation.

Drive Continuous Improvement

• Develop and optimize control strategies, process improvements, and automation solutions that enhance manufacturing performance.
• Identify and implement opportunities to improve safety, reliability, and operational efficiency.
• Leverage process data and system analytics to support informed decision-making and performance improvements.
• Create and maintain technical documentation, standards, and training materials to strengthen plant capabilities.
• Provide technical guidance and mentorship to maintenance, operations, and engineering personnel.

Lead Key Initiatives

• Support and lead automation projects as needed to improve production capabilities and plant performance.
• Assist with project scoping, technical specifications, vendor coordination, and implementation activities.
• Manage automation upgrades and equipment improvements while ensuring minimal disruption to production.
• Evaluate and integrate new technologies that support long-term operational and manufacturing objectives.

Qualifications

Education/Experience

• Bachelor's degree in Electrical Engineering, Controls Engineering, Automation Engineering, Computer Science, Engineering Technology, or a related technical field; or an equivalent combination of education and relevant work experience to successfully perform the essential functions of the position.
• 6+ years of plant engineering experience with 3 years of project engineering experience in a manufacturing environment. Experience programming and troubleshooting Allen-Bradley/Rockwell, ABB, and/or Siemens platforms.
• Experience supporting rolling mills, metal processing, slitting operations, winding/unwinding systems, or similar industrial manufacturing processes.

Knowledge/Skills/Abilities

• Experience with HMI development and visualization software.
• Experience integrating PLCs, HMIs, PCs, drives, networks, and third-party automation equipment.
• Experience with ABB DCS systems.
• Experience with SQL, .NET, Historian platforms, or manufacturing data systems.
• Experience with NFPA, NEC, ANSI Machine Safety standards, and industrial safety requirements.
• Strong knowledge of industrial automation systems, process control, instrumentation, and electrical systems.
• Strong troubleshooting and problem-solving skills.
• Ability to communicate complex technical concepts to both technical and non-technical audiences.