Controls Engineer

Job Title: Controls Engineer

Job Description

The Controls Engineer designs, programs, and supports complete automation systems for manufacturing operations, taking ownership of projects from initial concept through startup and commissioning. This role combines electrical design, PLC and robot programming, panel layout, and hands-on troubleshooting of complex equipment to improve plant performance, reliability, and safety. You will work closely with cross-functional teams and customers, leading installations and startups while ensuring systems meet technical, safety, and budget requirements.

Responsibilities

• Design complete automation systems using AutoCAD Electrical, including power distribution, I/O control, communications, and detailed control panel layout drawings.
• Calculate panel short-circuit current rating (SCCR), power rating, and full load amperage (FLA) to determine appropriate panel ratings.
• Develop, configure, debug, and test PLC and robot programs for new and existing equipment on the shop floor.
• Direct and support electrical assembly during equipment build, ensuring adherence to design specifications and industry standards.
• Lead and assist electrical assembly and integration activities during equipment installation at the plant.
• Lead start-up projects from initial commissioning through completion, coordinating efforts with internal teams and external stakeholders.
• Manage project time and costs to keep work within established budgets and schedules.
• Respond promptly to unplanned downtime and machine breakdowns, diagnosing issues and implementing effective corrective actions.
• Plan and execute maintenance activities for non-routine problems or issues on manufacturing and facility equipment.
• Troubleshoot routine and complex equipment and system problems using structured methods to identify and resolve root causes.
• Design, fabricate, and install mechanical and electronic equipment, including performing necessary program changes to support modifications.
• Lead and assist in planning, coordinating, and performing shutdowns and major maintenance activities.
• Complete required training and provide on-the-job training (OJT) to other employees as needed.
• Wire and repair electric motors and perform basic electrical wiring work in accordance with the National Electrical Code (NEC).
• Maintain and troubleshoot AC drive systems and PLCs, accessing and interpreting PLC logic via laptop or other devices using appropriate communication tools.
• Perform scheduled and unscheduled maintenance on plant equipment, including lubrication, repairs, adjustments, cleaning, and troubleshooting.
• Advise equipment operators and other personnel on operating procedures and safety requirements when working with electrical, electronic, and mechanical equipment and components.
• Install, start up, and shut down equipment in accordance with established safety procedures.
• Perform lockout/tagout procedures to ensure safe work conditions during maintenance and installation activities.
• Serve as the main customer interface during project installations, ensuring clear communication and successful project delivery.
• Carry out additional duties as assigned to support plant operations and continuous improvement initiatives.

Essential Skills

• Bachelor of Science degree in Engineering is required.
• Preferably 25+ years of engineering experience in building controls, machine tools, and troubleshooting control systems.
• Strong experience in PLC programming and automation controls engineering.
• Proficiency in electrical troubleshooting for complex manufacturing and facility equipment.
• Hands-on experience with PLC platforms and protocols, including Allen-Bradley RSLogix, Siemens Step 5 and Step 7, GE Machine Edition, and Mitsubishi systems.
• Experience setting up and utilizing industrial networks such as DeviceNet, Profibus, ProfiNet, Ethernet, and Ethernet/IP.
• Ability to set up and configure HMI screens and panels, including Allen-Bradley, Siemens, and Automation Direct interfaces.
• Experience with variable frequency drives (VFDs), including installation, repair, and programming of ABB, Parker, Allen-Bradley, Yaskawa, and Siemens drives.
• Robot programming experience, with Fanuc robots preferred.
• Vision system programming experience, with Cognex and Fanuc iRVision preferred.
• Proficiency with AutoCAD Electrical for electrical design and panel layout.
• Excellent written and verbal communication skills, with the ability to communicate effectively at all organizational levels.
• Demonstrated ability to lead projects at installation and act as the primary customer interface.
• Solid understanding of RIA robot safety standards, OSHA safety standards, and NFPA 79 and NFPA 70E electrical safety standards.
• Strong troubleshooting skills in programming, robotics, PLCs, and automation systems.

Additional Skills & Qualifications

• Experience designing and supporting controls for machine tools and automated manufacturing equipment.
• Experience in controls engineering for advanced automation technologies, robotics, PLCs, and machine vision systems.
• Ability to design and interpret CAD drawings for electrical and control systems.
• Comfort working on high-visibility projects that impact manufacturing performance and continuous improvement.
• Ability to collaborate effectively with cross-functional teams, including engineering, maintenance, operations, and external partners.
• Commitment to innovation, safety, and continuous professional development.
• Willingness to take ownership of projects from design through startup and commissioning, ensuring technical and safety compliance.
• Physical ability to lift up to 50 pounds as needed in the course of duties.
• Ability to work at heights on occasion to install, inspect, or maintain equipment.

Work Environment

This is a full-time, on-site role in a manufacturing environment that involves working closely with advanced automation technologies, robotics, PLCs, machine vision systems, and complex production equipment. The position requires flexibility to work any shift, as well as overtime, weekends, and holidays, based on operational needs. You will spend significant time on the plant floor, standing for long periods while performing equipment installation, maintenance, troubleshooting, and commissioning activities. The work setting can include exposure to varying temperatures (cold and heat), noise, dust, fumes, paint, chemicals, and oils, and may occasionally require working at heights. The environment emphasizes safety, collaboration, and continuous improvement, with a culture that values innovation, hands-on problem solving, and long-term professional growth.

This is a Permanent position based out of Hartselle, AL.

The pay range for this position is $80000.00 - $140000.00/yr.

Individual compensation offered for this position within this range will depend on many factors, including qualifications, skills, relevant experience, job knowledge, geographic location, internal equity, and other pertinent job-related factors.

Benefits & Perks Competitive compensation package Comprehensive health, dental, and vision insurance options Retirement savings plan with company-sponsored benefits Paid time off and company-recognized holidays Career development and advancement opportunities Hands-on exposure to advanced manufacturing, automation, robotics, and controls technologies Opportunity to work for a stable, growing organization with significant investment in manufacturing operations Collaborative team environment focused on innovation, safety, and continuous improvement

This is a fully onsite position in Hartselle,AL.

This position is anticipated to close on Oct 2, 2026.

About Actalent

Actalent is a global leader in engineering and sciences services and talent solutions. We help visionary companies advance their engineering and science initiatives through access to specialized experts who drive scale, innovation and speed to market. With a network of almost 20,000 consultants and 5,000 clients across the U.S., Canada, Asia and Europe, Actalent serves many of the Fortune 500. We are proud to be an Engineering News-Record (ENR) Top 500 Design Firm for our engineering design services and a ClearlyRated Best of Staffing® winner for both client and talent service.

The company is an equal opportunity employer and will consider all applications without regard to race, sex, age, color, religion, national origin, veteran status, disability, sexual orientation, gender identity, genetic information or any characteristic protected by law.

If you would like to request a reasonable accommodation, such as the modification or adjustment of the job application process or interviewing process due to a disability, please email View email address on click.appcast.io for other accommodation options.

San Francisco Fair Chance Ordinance: Pursuant to the San Francisco Fair Chance Ordinance, for all positions located in the city and county of San Francisco, we will consider for employment qualified applicants with arrest and conviction records.

Massachusetts Lie Detector: It is unlawful in Massachusetts to require or administer a lie detector test as a condition of employment or continued employment. An employer who violates this law shall be subject to criminal penalties and civil liability.

Use of Artificial Intelligence (AI): We may use Artificial Intelligence (AI) to support parts of our hiring process, including sourcing, screening, and evaluating candidates. AI helps assess applications and qualifications, but final decisions are made by our hiring team. By applying, you acknowledge and agree that your application may be reviewed using AI tools.