Sr. Controls Engineer (Warehouse Support)

Job Summary The Warehouse PLC / Controls Engineer is responsible for maintaining, troubleshooting, and improving automated control systems within a warehouse or distribution environment, maximizing system uptime through rapid issue resolution, preventive maintenance, and continuous improvement of PLC-controlled equipment such as conveyors, sortation systems, and automated material handling systems. Responsibilities Diagnose and resolve Programmable Logic Control (PLC), Human Machine Interface (HMI), and control system issues impacting warehouse operations. Provide real‑time support to operations teams to minimize downtime. Analyze system faults, alarms, and logs to identify root causes and implement corrective actions. Support troubleshooting of automation systems including conveyors, sorters, pick‑by‑light, and robotics systems. Develop and maintain accurate as-built documentation for PLC programs, network architecture, and control systems. Update electrical schematics, I/O lists, and system configurations as modifications occur. Create and continuously improve standardized troubleshooting guides and procedures. Develop training materials and provide guidance to operators and maintenance technicians. Capture lessons learned from recurring issues to build robust knowledge bases. Identify opportunities for system improvements to enhance reliability, efficiency, and performance. Propose and implement equipment upgrades, control logic enhancements, and process optimizations. Collaborate with vendors and engineering teams on system modifications and new installations. Develop and execute preventive maintenance strategies for PLCs, control panels, and automation systems. Monitor system health and implement predictive maintenance techniques to prevent failures. Ensure compliance with maintenance schedules to maximize uptime and equipment lifespan. Support commissioning of new equipment, system upgrades, and retrofit projects. Conduct Factory and site acceptance testing, verifying proper operation of safety circuits and compliance with standards. Documentation Maintain accurate as-built documentation for PLC programs and network architecture. Ensure documentation is organized, version-controlled, and easily accessible. Troubleshooting Guides & Knowledge Sharing Create and continuously improve troubleshooting guides and procedures. Develop training materials and provide guidance to operators and maintenance technicians. Capture lessons learned to build robust knowledge bases. Continuous Improvement & Upgrades Identify opportunities for system improvements to enhance reliability, efficiency, and performance. Propose and implement equipment upgrades, control logic enhancements, and process optimizations. Collaborate with vendors and engineering teams on system modifications and new installations. Preventive & Predictive Maintenance Develop and execute preventive maintenance strategies for PLCs and automation systems. Implement predictive maintenance techniques to prevent failures. Ensure compliance with maintenance schedules. Testing & Commissioning Support commissioning of new equipment and system upgrades. Conduct Factory and site acceptance testing and validate system performance post‑implementation. Verify safety circuits and compliance with standards. Required Qualifications Bachelor’s degree in Engineering (Electrical or Controls Engineering preferred) or equivalent work experience. 4‑7+ years of experience with PLC programming and troubleshooting (preferably Allen‑Bradley). FDA‑regulated manufacturing, consumer packaged goods, or similar experience. Experience with validation or commissioning documentation. Knowledge of PLCs, HMIs, VFDs, and industrial networks (EtherNet/IP, Profibus, etc.). Electrical systems and control panels experience. Proven ability to troubleshoot complex automation issues under time pressure. Preferred Qualifications Experience in warehouse automation, distribution centers, or material handling systems. Experience with WMS and other IT/OT systems integration. Working knowledge of quality software engineering principles described by FDA‑recognized standards. Programming experience using C#, HTML, SQL, or other software development languages. Familiarity with Continuous Improvement tools (Six Sigma, Lean, Kaizen, etc.). Ability to manage multiple tasks and prioritize the workday. Creative problem‑solving and ‘out‑of‑the‑box’ thinking. Key Skills Strong analytical and problem‑solving skills. Hands‑on troubleshooting expertise. Clear technical documentation ability. Continuous improvement mindset. Effective communication with cross‑functional teams. Benefits Free medical coverage in the Health Investment Plan (HIP) PPO medical plan. Excellent retirement savings plan with high employer contribution. Tuition reimbursement and the Freedom 2 Save student debt program. FreeU education benefit for obtaining a bachelor’s degree. Compensation Base pay ranging from $78,000.00 to $156,000.00 (may vary by location). Location & Travel North Chicago, IL. Traveling up to 5% of the time. Relocation assistance is not authorized for this position. Equal Employment Opportunity Abbott is an Equal Opportunity Employer, committed to employee diversity. Abbott welcomes and encourages diversity in our workforce. For more information, see the relevant EEO statements and links. #J-18808-Ljbffr Abbott Laboratories