Controls Engineer

Controls Engineer
Automation / Manufacturing Engineering Department Automation / Manufacturing Engineering Reports To Engineering Manager Employment Type Full-Time, Exempt / Salaried
Position Summary
The Controls Engineer leads the design, programming, integration, and continuous improvement of automation and controls systems across the facility. This role is responsible for the full lifecycle of automation on equipment including welding cells, laser and plasma cutting systems, CNC saws, CNC brake presses, powder coating lines, and assembly operations. The Controls Engineer works directly with industrial and collaborative robots and controls hardware from all major PLC and automation vendors, driving standardization, uptime, and safety across the plant floor.
Key Responsibilities
Controls & Robot Programming

• Design, program, and commission PLC, HMI, and robot control systems for new and existing production equipment.
• Lead integration of industrial robots and collaborative robots (cobots) into manufacturing cells, including end-of-arm tooling coordination, safety zoning, and cycle-time optimization.
• Program, troubleshoot, and maintain controls across welding machines, laser/plasma cutting systems, CNC saws, CNC brake presses, powder coating equipment, and automated/manual assembly stations.
• PLC logic, HMI screens, and robot programs across major platforms (e.g., Allen-Bradley/Rockwell, Siemens, Mitsubishi, Omron, Fanuc, ABB, Universal Robots, KUKA).

Systems Design & Safety

• Design and specify control panels, I/O architecture, safety circuits, and networking (Ethernet/IP, PROFINET, DeviceNet, etc.) for new installations and retrofits.
• Perform risk assessments and ensure controls and robotic systems comply with applicable safety standards (e.g., ISO 10218-1/2, ISO/TS 15066, NFPA 79, CSA Z434, OSHA/CCOHS as applicable).

Troubleshooting & Continuous Improvement

• Lead root-cause troubleshooting of controls-related downtime; drive corrective and preventive actions.
• Partner with Continuous Improvement, Maintenance, and Production teams to identify and implement automation opportunities that improve safety, quality, throughput, and cost.
• Evaluate new automation technologies and vendors to support long-term facility automation strategy.

Project Management & Documentation

• Manage automation projects from concept through commissioning, including scoping, budgeting, vendor coordination, and documentation.
• Create and maintain electrical schematics, controls documentation, program backups, and standard work for controls systems.
• Provide technical mentorship to maintenance technicians and junior engineers on controls and robotics.

Qualifications
Required

• Bachelor's degree in Electrical Engineering, Mechatronics, Controls Engineering, or related field, or equivalent hands-on experience.
• 5+ years of experience in industrial controls engineering within a manufacturing environment.
• Hands-on programming experience with multiple major PLC platforms (e.g., Rockwell/Allen-Bradley, Siemens, Mitsubishi).
• Experience integrating and programming industrial robots and/or collaborative robots in a production setting.
• Strong knowledge of electrical control systems, motor controls, drives, sensors, and industrial networking protocols.
• Working knowledge of robotic and machine safety standards (ISO 10218, ISO/TS 15066, or equivalent).
• Experience reading and developing electrical schematics and P&IDs.
• Strong troubleshooting skills with the ability to work directly on the plant floor under production pressure.

Preferred

• Experience with fabrication/metalworking equipment controls: welding, laser/plasma cutting, CNC saws, CNC brake presses, or powder coating lines.
• Experience with vision systems, robotic weld cells, or CNC machine interfacing (e.g., load/unload automation).
• Familiarity with SCADA/MES systems and data integration between controls and ERP platforms (e.g., SAP S/4HANA).
• Experience with safety-rated controllers and functional safety configuration (e.g., safety PLCs, safety-rated robot controllers).
• Six Sigma, Lean Manufacturing, or Continuous Improvement certification/experience.
• Experience managing capital automation projects, including budget and vendor management.

Working Conditions

• Ability to work on the manufacturing floor around active machinery, welding operations, and material handling equipment.
• Ability to climb, kneel, and work in confined spaces around machine cells as needed.
• Use of appropriate PPE required in designated areas (safety glasses, hearing protection, welding shade, etc.).
• Occasional lifting up to 25-35 lbs.

What We Offer

• Competitive salary commensurate with experience
• Benefits package - health, dental, vision, retirement matching
• Opportunity to lead automation strategy at a growing manufacturing facility
• Exposure to a wide range of equipment and controls technologies across a full production floor

The Coats Company is an equal opportunity employer that evaluates qualified applicants without regard to race, color, national origin, religion, ancestry, sex (including pregnancy, childbirth and related medical conditions), age, marital status, disability, veteran status, citizenship status, sexual orientation, gender identity or expression, and other characteristics protected by law.