Lead Controls Engineer

Lead Controls Engineer

Location: Holcomb, KS 67851
Type: Full-Time

Job Summary

We are seeking a Lead Controls Engineer to provide technical leadership for industrial automation, plant controls, and technology-driven manufacturing operations. This role will program, commission, troubleshoot, and modernize control systems while supporting plant uptime and mission-critical operations. The engineer will work across PLCs, HMI/SCADA, industrial networks, electrical systems, and automated material-handling equipment .

Key Responsibilities

• Provide technical leadership for plant automation, controls, system development, and technology-based processes.
• Program, commission, and troubleshoot PLC-based control systems using ladder logic, structured text, and I/O mapping, with emphasis on Schneider Electric/Modicon platforms.
• Diagnose and resolve complex issues involving PLCs, electrical circuits, industrial communications, mechanical equipment, and control systems .
• Troubleshoot automated material-handling equipment, including conveyors, motors, drives, sensors, photo eyes, interlocks, and sequencing logic .
• Maintain and troubleshoot Ignition and GE iFIX SCADA/HMI platforms.
• Integrate and troubleshoot Keyence, Cognex, and SICK barcode scanning and vision systems.
• Troubleshoot industrial communication protocols between PLCs, field devices, HMIs, scanners, and enterprise IT systems.
• Support legacy systems and lead controls upgrades, component replacements, and automation modernization projects.
• Establish and maintain IT/OT standards, coding standards, SDLC methodologies, operational procedures, and technical documentation .
• Manage technical vendors, evaluate technology proposals, and support hardware/software purchasing decisions.
• Develop integrated test plans, evaluate technical solutions, and collaborate with technical and non-technical stakeholders.

Required Skills & Experience

• Bachelor's degree in Computer Science, Information Systems, Engineering, or a related technical discipline ; equivalent experience accepted.
• 6+ years of experience in Information Systems, Controls Engineering, Industrial Automation, or a related field, with proven programming experience.
• Advanced knowledge of PLC programming, commissioning, troubleshooting, ladder logic, structured programming, I/O mapping, and electrical schematic interpretation .
• Strong knowledge of SCADA, 4GL programming, scripting languages, server-based systems, and SQL .
• Advanced experience with SDLC methodologies, code reviews, technical specifications, and integrated test execution .
• Strong troubleshooting, root-cause analysis, and problem-solving skills across controls, electrical, mechanical, and communication systems.
• Excellent verbal and written communication skills , with the ability to explain complex technical concepts to non-technical audiences.
• Ability to apply basic project management practices and work effectively with cross-functional teams.

Preferred Qualifications

• Extensive experience with Schneider Electric/Modicon PLC hardware and programming software .
• Experience with Ignition and GE iFIX SCADA/HMI .
• Experience integrating and troubleshooting Keyence, Cognex, and SICK industrial vision/scanning systems.