Controls Engineer

Controls Engineer

PLC-Based Automation | Industrial Controls | Startup & Commissioning

Location: Norcross, GA

Employment: Full-Time

Reports To: Engineering Manager

Compensation: Competitive, Based on Experience

Travel: Approximately 25%, for on-site commissioning of machines

Position Overview

We are seeking a Controls or Electrical Engineer with 3+ years of experience supporting PLC-based automation and robotic systems, industrial electrical controls, and automated manufacturing equipment in production environments.

This role is responsible for commissioning, startup-support, and ongoing troubleshooting and testing of automated production equipment. You will work hands-on with Beckhoff PLC and motion platforms, Cobots such as Universal Robotics, HMI/SCADA systems, and industrial control networks.

This position includes approximately 25% travel to support on-site machine commissioning. The ideal candidate combines strong technical depth with a proven ability to reduce downtime, improve equipment reliability, and optimize production processes through effective root cause analysis and control system enhancements.

Key Responsibilities

• Commission new and upgraded automation systems, including PLC programming, panel wiring verification, I/O checkout, and loop checks.
• Provide startup support for new equipment installations, coordinating with vendors, integrators, and internal engineering/operations teams.
• Troubleshoot and support startup of existing production machines, diagnosing control and mechanical/electrical faults to restore equipment to running condition.
• Troubleshoot ladder logic, structured text, other IEC61131-3 programming structures
• Diagnose and resolve electrical control issues including motor controls, VFDs, Servo Motion, remote I/O, safety circuits, E-stops, and interlocks.
• Configure and support HMI/SCADA systems for operator visibility and control
• Configure and troubleshoot industrial networks (EtherNet/IP, Ethercat, Profibus, DeviceNet, Modbus TCP/RTU, OPC-UA).
• Interpret and maintain electrical schematics, blueprints, BOMs, loop drawings, control layouts, and documentation using SkyCAD, AutoCAD Electrical, or EPLAN P8.
• Conduct root cause analysis on equipment breakdowns and alarms, driving downtime reduction and reliability improvements.
• Collaborate cross-functionally with operations, maintenance, and engineering teams to support production schedules and continuous improvement initiatives.
• Ensure all work complies with safety standards, including safety systems, SIL requirements, OSHA regulations, and Lockout/Tagout (LOTO) procedures.
• Travel approximately 25% of the time to customer or facility sites to support on-site commissioning, startup, and troubleshooting of machines.
• Maintain SOP compliance and support development of standardized commissioning and troubleshooting procedures.

Required Qualifications

• 3+ years of experience supporting PLC-based automation systems, industrial electrical controls, and automated manufacturing equipment in a production environment.
• Associate's or Bachelor's degree in Electrical Engineering, Electronics, Controls/Automation Technology, or related field (equivalent hands-on experience will be considered in lieu of a degree).
• Hands-on experience programming and troubleshooting PLCs, Cobots, and HMIs.
• Proficiency in ladder logic, structured text, FBD, or SFC programming languages, with strong I/O diagnostics skills.
• Experience with HMI/SCADA platforms such as Blazor
• Working knowledge of industrial networking protocols: EtherNet/IP, EtherCAT, Profibus, DeviceNet, Modbus TCP/RTU, OPC-UA.
• Ability to read and interpret electrical schematics, with proficiency in SkyCAD or AutoCAD preferred
• Proven ability to troubleshoot and support startup of existing production machines, diagnosing and resolving faults to restore equipment to running condition.
• Demonstrated experience with field commissioning, loop checks, and equipment start-up support.
• Strong understanding of industrial safety standards, including LOTO procedures and safety circuit design (E-stops, interlocks, safety relays).
• Effective communicator able to collaborate across operations, maintenance, and engineering functions.

Preferred Qualifications

• Experience with Beckhoff TwinCAT or other Structured Text based PLC systems
• Experience with safety PLCs and SIL-rated safety systems.
• Experience supporting multi-vendor automation environments in a fast-paced manufacturing setting.

Work Environment

This position works primarily on the production floor in an industrial manufacturing environment, with exposure to moving machinery, electrical panels, and standard plant conditions. The employee must be able to safely enter production areas, work around energized equipment following LOTO procedures, and use required personal protective equipment.

This role requires approximately 25% travel, primarily for on-site commissioning of machines at customer or facility locations. Reasonable accommodations may be made to enable qualified individuals to perform the essential functions. This description is not an exhaustive list of duties; compensation range and shift schedule should be confirmed prior to publication.