Lead Controls Engineer

Lead Controls Engineer

Location: Holcomb, KS 67851
Contract: 12 Months
Schedule: 8-hour shifts; no overtime after 40 hours/week. 10-hour shifts preferred for tie-in meetings.

Job Summary

We are seeking an experienced Lead Controls Engineer to provide technical leadership for industrial automation, plant controls, and IT/OT environments in a manufacturing facility. This role will support PLC programming, SCADA/HMI systems, industrial networks, automated material-handling equipment, troubleshooting, and controls modernization initiatives.

The ideal candidate will have strong hands-on experience with Schneider Electric/Modicon PLCs, Ignition, GE iFix, and industrial vision/scanning systems , along with the ability to troubleshoot complex controls issues in a live manufacturing environment.

Key Responsibilities

• Provide technical leadership for plant automation, controls systems, and technology-based processes.
• Program, commission, troubleshoot, and maintain PLC-based control systems using ladder logic, structured text, and I/O mapping.
• Work extensively with Schneider Electric/Modicon PLCs and related programming software.
• Diagnose complex issues involving PLCs, electrical circuits, industrial networks, communications, and mechanical equipment.
• Troubleshoot automated material-handling systems, including conveyors, motors, drives, sensors, photo eyes, interlocks, and sequencing logic.
• Maintain and troubleshoot SCADA/HMI systems , including Ignition and GE iFix .
• Integrate and troubleshoot industrial barcode scanners and vision systems, including Keyence, Cognex, and SICK .
• Troubleshoot industrial communication protocols between PLCs, field devices, HMIs, scanners, and enterprise IT systems.
• Support legacy control systems and lead controls upgrades, component replacements, and automation modernization projects.
• Develop and maintain technical standards, coding standards, SDLC methodologies, and operational procedures.
• Develop technical specifications, test plans, and integrated testing processes.
• Evaluate technical solutions, hardware, software, and vendor proposals.
• Coordinate with vendors and cross-functional teams on controls and automation initiatives.
• Communicate complex technical issues and solutions effectively to technical and non-technical stakeholders.
• Support continuous improvement, system reliability, and plant operational uptime.

Required Qualifications

• Bachelor's degree in Engineering, Computer Science, Information Systems, or a related technical field ; equivalent experience may be considered.
• 6+ years of experience in Controls Engineering, Information Systems, Industrial Automation, or a related field.
• Strong hands-on experience with PLC programming, commissioning, troubleshooting, ladder logic, structured text/programming, and I/O mapping .
• Ability to read and interpret electrical schematics .
• Extensive experience with Schneider Electric/Modicon PLC hardware and programming software .
• Experience with Ignition and GE iFix SCADA/HMI platforms .
• Experience integrating and troubleshooting Keyence, Cognex, and SICK vision/scanning systems.
• Strong understanding of industrial automation, controls, SCADA, HMI, and industrial communication networks.
• Working knowledge of scripting languages, SQL, server-based systems, and related industrial technologies.
• Experience with SDLC, code reviews, technical specifications, and integrated testing .
• Strong troubleshooting, analytical, communication, and problem-solving skills.
• Ability to work effectively with engineering, operations, IT/OT, vendors, and other cross-functional teams.