Controls Engineer

The Controls Engineer will provide leadership and technical expertise in controls and electronic circuitry to help a new medical device manufacturing plant hit launch, safety, quality, and productivity targets. Initial focus is on specifying through commissioning new high-volume medical device assembly equipment, machine networks, and SCADA systems. The role then shifts toward controls improvements and troubleshooting of high-volume automated medical device assembly equipment and associated electrical wiring/devices, instrumentation, embedded systems, motion control, and inspection systems. This person will also train maintenance, production, and other personnel on technical troubleshooting. The ideal candidate is skilled in designing, specifying, installing, and maintaining PLC- and PC-based controls in a manufacturing environment. Responsibilities Develop specifications and user requirements for controls, communication, and SCADA systems for high-volume medical device assembly and material handling equipment Oversee electrical/controls design and build by machine OEMs to ensure equipment meets specifications, safety, and performance requirements Support installation, FAT/SAT, validation, and commissioning of assembly and material handling equipment Lead or support maintenance teams in troubleshooting downtime and quality issues; identify and correct root causes of chronic equipment failures Develop and implement plans for effective controls troubleshooting and repair to minimize downtime Manage control of machine software, firmware, and user access security Propose, risk-assess, and implement PLC program and other software/firmware/hardware changes to improve safety, yield, and productivity Complete change control documentation, including risk assessment and justification Optimize/improve human-machine interfaces, SCADA systems, and MES interfaces Troubleshoot and optimize performance of vision inspection systems Define equipment maintenance/preventative maintenance requirements and procedures Identify root causes of equipment failures; develop and implement corrective actions Develop troubleshooting and repair skills of Controls and Automation Technicians Provide expert on-call support for system outages and major incidents Work with Automation and Validation Engineers to develop test scripts validating software/firmware updates for controls-related changes Qualifications Bachelor of Science in Electrical Engineering or equivalent, with 7+ years of experience in a high-volume industrial/manufacturing environment Proficiency programming and troubleshooting Allen Bradley ControlLogix PLCs and HMI/GUI Proficient with RSLogix5000, Logix Designer, Studio 5000, FactoryTalk SE, Ignition, and Cognex Demonstrated ability to design fault-tolerant systems with error handling and recovery General understanding of factory LAN/WAN Ethernet networks; able to set up devices with IP addresses/nodes Experience setting up, tuning, and troubleshooting Allen Bradley PowerFlex VFDs and Kinetix multi-axis servo drives Solid working knowledge of: Fieldbus networks (ProfiNet, DeviceNet, Ethernet/IP, safety-rated fieldbus networks) RFID devices and components (receiver, antenna, puck, reader) PID tuning and closed feedback loops Serial communication (RS-232, RS-422, RS-485, ProfiBus, Modbus RTU, Data Highway) between PLCs, instruments, and microcontrollers Ethernet communications between machine PLCs and embedded data collection systems Proficiency selecting appropriate circuit protectors, wire/cable, sensors, safety hardware, PLC hardware, remote I/O, VFD, and instrumentation Broad knowledge of controls devices and troubleshooting Strong written and verbal communication skills Preferred Skills Equipment engineering experience within the medical device industry highly desirable Experience with vision systems (Cognex, Keyence, Fanuc) a plus Experience programming/troubleshooting Beckhoff or B&R (ABB) PLCs #J-18808-Ljbffr Intellectt Inc