Controls Engineer

Job Description

Job Description

As a Controls Engineer at Automation Solutions, you will help design, program, commission, integrate, and support custom automated and robotic systems. This is a hands-on engineering position involving both hardware and software, with responsibility for supporting projects from initial concept through installation and post-delivery support.

The Controls Engineer will work with PLCs, HMIs, variable frequency drives, servo systems, robots, vision systems, and other industrial automation technologies. The position includes work at our Birmingham facility and at customer locations, with approximately 25% travel required as necessary to support system commissioning, installation, troubleshooting, and service.

Successful candidates will demonstrate strong technical aptitude, practical industrial controls experience, and a commitment to delivering innovative, reliable, and high-quality automation solutions. The ideal candidate is organized, self-motivated, comfortable working both independently and collaboratively, and capable of managing multiple assignments simultaneously.

Primary Responsibilities Collaboration and Project Support

• Report to the Controls Engineering Manager regarding daily priorities, assignments, and technical direction.
• Receive project-specific direction from members of the Automation Solutions management and engineering teams as needed.
• Coordinate with sales, project management, controls engineering, mechanical engineering, fabrication, and installation teams to design and implement automation projects.
• Communicate directly with customers to understand requirements, address technical concerns, solve problems, and provide high-quality service.
• Provide technical guidance and oversight during control-panel fabrication, system wiring, equipment assembly, and installation.
• Maintain clear communication regarding project progress, technical concerns, schedule risks, and required customer support.

Controls Engineering and Integration

• Design, develop, program, integrate, and troubleshoot automated electromechanical control systems.
• Develop, modify, and troubleshoot PLC and HMI programs, including ladder logic and related industrial control programming.
• Program and troubleshoot PLCs, HMIs, VFDs, servo systems, robots, vision systems, and other automated control equipment.
• Review and interpret electrical drawings, specifications, sequences of operation, and other project documentation.
• Support the development and revision of electrical drawings and control-system documentation.
• Perform hands-on integration, modification, troubleshooting, and repair of robotic, mechanical, electrical, and controls equipment.
• Participate in system testing and runoffs to verify that equipment functionality meets contractual and customer requirements.
• Conduct quality-control inspections and help ensure compliance with applicable company safety requirements and electrical codes.
• Identify technical issues, determine root causes, and implement practical corrective actions.

Commissioning, Installation, and Customer Support

• Provide hands-on support for the assembly, testing, commissioning, and installation of automated manufacturing equipment.
• Travel to customer facilities as necessary, approximately 25%, to support installation, commissioning, startup, troubleshooting, training, and post-delivery service.
• Use electrical test equipment, hand tools, power tools, and other equipment required to complete assigned work.
• Troubleshoot, diagnose, modify, and repair electromechanical control systems at Automation Solutions and customer facilities.
• Support customer production startup and resolve controls-related issues that arise during commissioning.
• Maintain accurate and up-to-date records of programming changes, troubleshooting activities, completed work, and system configurations.
• Perform quality-control inspections of electrical control systems, panels, field wiring, and installed equipment.
• Represent Automation Solutions professionally while working at customer facilities.

Shop and Workplace Responsibilities

• Maintain a clean, safe, and organized work area.
• Assist with general housekeeping throughout the fabrication and shop areas, including organizing materials and parts, removing trash, and sweeping floors.
• Follow company safety procedures and use required personal protective equipment.
• Work safely around energized electrical systems, industrial machinery, robotic equipment, and other automated systems.

Qualifications Education

• Associate degree in Electrical Engineering Technology, Mechatronics, Industrial Automation, or a related technical field is preferred.
• Bachelor’s degree in Electrical Engineering, Mechatronics, or a related field is preferred.
• Relevant industrial controls experience may be considered in place of a degree.

Experience

• Two to four years of controls programming or comparable industrial controls experience.

• Experience developing, modifying, troubleshooting, or supporting PLC programs and ladder logic.

• Experience with one or more of the following:- PLCs

  • HMIs
  • Variable frequency drives
  • Servo and motion-control systems
  • Industrial robots
  • Machine-vision systems
  • Industrial communication networks

• Experience reading and understanding electrical drawing sets.

• Hands-on experience integrating, modifying, troubleshooting, or repairing industrial control systems.

• Experience supporting custom machinery, automated manufacturing equipment, or robotic systems is preferred.

• Experience developing or revising electrical drawings is preferred.

• Experience with equipment commissioning, installation, startup, or field service is preferred.

Knowledge, Skills, and Abilities

• Strong industrial controls troubleshooting and problem-solving skills.
• Strong computer and technical software skills.
• Strong written and verbal communication skills.
• Experience with Allen-Bradley, Omron, Siemens, GE, or other industrial PLC platforms.
• Ability to troubleshoot electrical, mechanical, programming, networking, and system-integration issues.
• Ability to communicate technical information clearly to customers, engineers, technicians, and other project stakeholders.
• Ability to manage multiple assignments and adjust priorities based on project and customer needs.
• Ability to work effectively both independently and as part of a multidisciplinary team.
• Strong organizational and documentation skills.
• Self-motivated, dependable, and willing to take ownership of assigned work.
• Willingness and ability to perform hands-on work in both shop and field environments.

Travel and Field-Service Requirements

• Willingness and ability to travel approximately 25%, as necessary, based on project and customer requirements.
• Travel may include customer-site visits for equipment installation, commissioning, startup, troubleshooting, training, and post-delivery support.
• Some projects may require overnight travel.
• Travel frequency and duration may vary depending on project schedules and customer needs.
• Ability to work at industrial and manufacturing facilities while following customer-specific safety and access requirements.
• Possess and maintain a valid U.S. driver’s license and a driving record acceptable under company requirements.

Additional Employment Requirements

• Ability to pass applicable background checks.
• Ability to pass pre-employment and random drug screenings.
• Ability to comply with company and customer safety requirements.
• Ability to wear required personal protective equipment.

Physical Requirements

The physical requirements listed below are representative of those required to perform the essential functions of the position:

• Ability to lift and carry up to 50 pounds.
• Ability to stand and work on your feet for extended periods.
• Ability to bend, reach, climb, kneel, and perform hands-on work around industrial equipment.
• Ability to use electrical test equipment, hand tools, and power tools.
• Ability to work safely around automated machinery, robotic systems, electrical equipment, and industrial processes.
• Ability to wear required personal protective equipment.

Reasonable accommodations may be made to enable qualified individuals with disabilities to perform the essential functions of the position.

Why Join Automation Solutions?

• Work on diverse custom automation and robotic systems rather than supporting the same equipment every day.
• Participate in projects from initial concept through programming, testing, commissioning, installation, and customer support.
• Develop valuable skills across multiple industrial controls and automation technologies.
• Gain hands-on experience with PLCs, HMIs, VFDs, servo systems, robotics, machine vision, and industrial networks.
• Solve challenging, real-world manufacturing and automation problems.
• Work alongside experienced engineers, technicians, fabricators, and other automation professionals.
• Receive stable, full-time employment with opportunities for professional development and growth.
• See the systems you help design and program become fully functioning production equipment.

Automation Solutions and Livingston & Haven consider all qualified applicants without regard to age, race, color, national origin, sex, religion, veteran status, disability, sexual orientation, gender identity, or any other status protected by applicable law.

You should be proficient in:

• PLC Troubleshooting Skills
• Bachelor's Degree
• Electrical Schematics
• Troubleshooting Skills
• Machine Building/Assembling
• Single and Three Phase Power
• 120/208/240/480 Voltage Systems
• CAD Software
• Industrial Robot Programming
• Electrical Installation
• Troubleshooting Industrial Automation Equipment
• PLC Programming Experience
• SCADA Experience
• Programming Machine Vision Systems
• Electrical / Electronic Systems
• Pneumatics Troubleshooting
• Field Service Readiness
• Industrial Electrical Systems
• Electrical Schematic Reading
• Equipment Installation & Wiring

Machines & technologies you'll use:

• Variable Frequency Drives (VFD)
• CAD Software (AutoCAD, Autodesk Inventor)
• Programmable Logic Controller (PLC) (Fanuc, Allen Bradley, Omron, Siemens)
• Vision System (Keyence, Cognex, Omron, Banner)
• Servo Motors
• Industrial Robot (Fanuc, Kuka, ABB, Yaskawa Motoman, Universal Robotics, Nachi, Epson, Kawasaki)