Controls Technician

Controls Technician

Position Title: Controls Technician

Department: Engineering & Maintenance

Reports to: Engineering Manager

Classification: Exempt

Schedule: Full-time; overtime and occasional travel as required

Position Summary

The Controls Technician serves as the on-site subject matter expert for industrial automation, electrical controls, and process instrumentation. This role provides advanced technical leadership across PLC programming, HMI configuration, control panel design, and troubleshooting of complex automation systems. The Controls Technician drives system reliability, supports continuous improvement initiatives, and ensures controls best practices are consistently applied across equipment and processes.

Key Responsibilities

• Lead complex troubleshooting of PLCs, HMIs, VFDs, servos, instrumentation, and industrial networks.
• Perform high-level PLC logic modifications, HMI updates, and system tuning to improve process performance.
• Conduct advanced diagnostics on electrical and automation systems, including network communication issues, intermittent faults, and equipment failures.
• Validate machine safety circuits, interlocks, and safety PLC functionality.
• Support the design, development, and upgrade of control panels, electrical systems, and automation hardware.
• Review and refine electrical schematics, panel layouts, and device specifications.
• Integrate new equipment into existing automation architectures with minimal disruption to operations.
• Participate in engineering design reviews and recommend improvements for controls functionality, maintainability, and safety.
• Lead the controls portion of capital projects, improvement efforts, and system upgrades.
• Coordinate field installation work, including panel wiring, device calibration, and system commissioning.
• Assist with developing scopes of work and technical requirements for contractors and integrators.
• Execute FAT/SAT procedures and document results.
• Serve as the escalation point for technicians during high-impact equipment issues.
• Develop advanced troubleshooting guides, standards, and documentation to support site maintenance.
• Lead efforts to reduce equipment downtime, improve system reliability, and optimize equipment performance.
• Support root-cause investigations and implement corrective and preventive actions.
• Act as a technical liaison between Operations, Maintenance, Engineering, IT/OT, and external integrators.
• Support "Design for Operability" and "Design for Maintenance" discussions to enhance operator usability and system accessibility.
• Ensure system documentation, change logs, and version control are consistently maintained.
• Mentor junior technicians and provide hands-on training in PLC logic, electrical troubleshooting, and automation fundamentals.
• Lead knowledge-transfer sessions to improve troubleshooting efficiency and reduce MTTR across the maintenance team.

Required Qualifications & Skills

• High School Diploma or equivalent required; Associate degree in Electro-Mechanical Technology, Automation, or related field preferred.
• 2+ years of hands-on experience with industrial automation and controls systems.
• Strong competency with PLC/HMI platforms, motor control systems, and industrial networks.
• Ability to interpret complex electrical schematics, P&IDs, and technical drawings.
• Advanced troubleshooting and diagnostic skills for electrical and automation equipment.
• Strong understanding of AC/DC systems, three-phase power, and control circuit design.
• Effective communication skills with the ability to interface with both technical and non-technical stakeholders.
• Experience using CMMS software for work orders, inventory, and documentation.

Physical Requirements

• Ability to sit, stand, walk, and work in manufacturing environments for extended periods.
• Occasional lifting of up to 50 lbs.
• Ability to safely climb ladders and access elevated or confined equipment areas.
• Strong visual acuity for reading schematics, identifying wiring, and working with instrumentation.

Reporting Requirements

• Provide weekly updates on project status, system issues, and improvement progress.
• Participate in routine maintenance and engineering meetings.
• Maintain accurate documentation of electrical systems, automation changes, and inventory.

Disclaimer: The requirements and responsibilities outlined in this job description are intended to describe the general nature and level of work performed by the employee. This is not a complete list of all responsibilities, duties, and skills required. The company reserves the right to modify, add, or remove duties, as necessary.