Controls Engineer

Controls Engineer

This role focuses on designing, developing, and commissioning advanced industrial control systems for high-speed manufacturing, material handling, and process applications. You will architect PLC and HMI/SCADA solutions, integrate motion and safety systems, and support complex automation projects from concept through startup. The position offers the opportunity to work on diverse automation projects, collaborate with cross-functional teams, and grow professionally in a technically challenging and supportive environment.

Responsibilities

• Design, develop, and deploy comprehensive PLC programs using the Allen-Bradley Logix platform, including Studio 5000 and RSLogix 5000.
• Develop and configure HMI and SCADA applications to provide intuitive operator interfaces and robust system monitoring.
• Program and commission high-speed, multi-axis synchronized motion systems using Kinetix servo drives, virtual master axes, electronic gearing, and camming for precision manufacturing operations.
• Design, program, and optimize complex conveyor and material handling systems, including accumulation conveyors, sortation systems, palletizers, and handoffs with automated guided vehicles (AGVs) or autonomous mobile robots.
• Implement tracking, merging, diverting, and barcode or RFID scanning logic to ensure seamless product flow through high-throughput logistics and production lines.
• Design and optimize control strategies for web handling applications, including tension control, winding and unwinding, and registration for continuous web lines.
• Engineer control algorithms for extrusion processes, ensuring tight temperature regulation, pressure control, and line speed synchronization.
• Implement complex batch process sequences in alignment with industry standards such as ISA-88, ensuring reliable and repeatable operations.
• Design, tune, and troubleshoot advanced PID control loops, including cascade loops, ratio control, and feed-forward strategies to minimize disturbances and maximize process stability.
• Integrate third-party equipment, robotics, instrumentation, and vision systems into the primary control network using industrial communication protocols such as EtherNet/IP, ControlNet, and DeviceNet.
• Conduct rigorous factory acceptance testing (FAT) and site acceptance testing (SAT) to validate system performance and functionality.
• Perform on-site troubleshooting, debugging, and system startup activities to ensure successful commissioning and handover.
• Design and implement hardware and software safety systems compliant with relevant standards such as ISO and ANSI B11.19, using Allen-Bradley GuardLogix controllers and safety-rated components.
• Create and maintain detailed engineering documentation, including functional design specifications, control philosophy documents, I/O lists, cause-and-effect matrices, and comprehensive as-built code comments.
• Collaborate with cross-functional teams, communicate effectively with stakeholders, and provide technical leadership on projects in high-pressure manufacturing environments.
• Support continuous improvement initiatives by identifying opportunities to enhance system reliability, performance, and maintainability.

Essential Skills

• Bachelors degree in Electrical Engineering, Mechanical Engineering, Computer Engineering, or a related technical discipline, or equivalent practical experience.
• Minimum of 810 years of hands-on controls engineering experience in a manufacturing, machinery builder (OEM), or heavy industrial process environment.
• Expert-level proficiency with Allen-Bradley hardware and software ecosystems, including Logix controllers, GuardLogix, Studio 5000, PanelView Plus, and FactoryTalk View SE/ME.
• Strong experience in PLC programming with Allen-Bradley platforms, including development, testing, and troubleshooting.
• Demonstrated mastery of high-speed motion control and multi-axis coordination using servo drives and advanced motion profiles.
• Direct experience with continuous web handling lines, including tension control, winding and unwinding, and registration control.
• Experience in batch processing and continuous process industries, including implementation of ISA-88-based control strategies.
• Deep theoretical and practical knowledge of PID loop tuning, cascade control, ratio control, and feed-forward compensation.
• Extensive experience with conveyor systems and material handling automation architecture, including product tracking and routing.
• Familiarity with WMS (Warehouse Management Systems) or MES (Manufacturing Execution System) integration for material handling routing and data exchange.
• Strong working knowledge of industrial networking architecture, particularly Ethernet/IP topology, managed switches, VLANs, and device-level ring (DLR) configurations.
• Proven troubleshooting skills for complex control systems, including PLCs, motion systems, and industrial networks.
• Excellent cross-functional communication skills and the ability to work independently or lead projects in demanding production environments.
• Background in electrical and controls engineering, including reading and interpreting control schematics and documentation.

Additional Skills & Qualifications

• Experience designing and implementing safety systems compliant with standards such as ISO and ANSI B11.19 using safety-rated controllers and components.
• Hands-on experience with Kinetix servo drives, virtual master axes, electronic gearing, and camming for synchronized motion applications.
• Experience integrating robotics, vision systems, and third-party instrumentation into Allen-Bradley-based control architectures.
• Familiarity with barcode and RFID systems for product identification, tracking, and routing in high-throughput environments.
• Experience performing factory acceptance testing (FAT), site acceptance testing (SAT), and on-site commissioning for large automation projects.
• Ability to develop clear and comprehensive engineering documentation, including functional design specifications, I/O lists, and cause-and-effect matrices.
• Strong organizational skills and attention to detail when managing multiple projects and documentation sets.
• Interest in continuous learning and professional development in advanced automation, motion control, and industrial networking.
• Ability to mentor and support team members on complex controls engineering topics.

Work Environment

This is an onsite role that requires approximately 25% travel to customer locations throughout the United States for commissioning, testing, and support activities. You will work in industrial and manufacturing environments that may include high-speed production lines, heavy machinery, and automated material handling systems. The role involves frequent interaction with PLCs, HMIs, SCADA systems, servo drives, and industrial networks such as EtherNet/IP, ControlNet, and DeviceNet. Typical work includes time spent in both office settings for design and documentation and on the plant floor for testing, troubleshooting, and startup. The organization offers medical, dental, and vision insurance, a Health Savings Account with employer contribution, employer-paid life and AD&D insurance, voluntary supplemental insurance, a 401(k) plan with company match, paid time off and paid holidays, and applicable paid leave benefits. You will work in a collaborative, team-oriented culture with significant exposure to diverse automation projects and opportunities for professional growth and technical development.

Job Type & Location

This is a Permanent position based out of South Saint Paul, MN.

Pay and Benefits

The pay range for this position is $90000.00 - $130000.00/yr. Individual compensation offered for this position within this range will depend on many factors, including qualifications, skills, relevant experience, job knowledge, geographic location, internal equity, and other pertinent job-related factors.

In addition to competitive compensation, the following benefits are available to eligible employees: Medical, dental, and vision insurance Health Savings Account with employer contribution Nice Healthcare Employer-paid life and AD&D insurance Voluntary supplemental insurance 401(k) plan with company match Paid time off and paid holidays Minnesota ESST and applicable paid leave benefits Opportunities for professional growth and technical development Collaborative, team-oriented culture with exposure to diverse automation projects

Workplace Type

This is a fully onsite position in South Saint Paul, MN.

Application Deadline

This position is anticipated to close on Oct 5, 2026.