Controls Engineer (Manufacturing Environment)

Controls Engineer

Cérélia's newly established Frozen Breakfast Business Unit – US Waffle – is driving an ambitious growth strategy, backed by two manufacturing facilities, Liberty, SC, and Hazelwood, MO. To effectively support the rapid scaling of operations at our state-of-the-art Hazelwood facility, US Waffle is seeking a dynamic and skilled Controls Engineer to join our team in Hazelwood, MO. This role is responsible for supporting and advancing the plant's automation, controls, and electrical systems to ensure reliable, efficient, and scalable manufacturing operations. The Controls Engineer will own PLC, HMI, and SCADA systems across the facility, ensuring uptime, troubleshooting complex issues, and supporting new equipment integration and capital projects. This role is critical in driving automation performance, reducing downtime, and building technical capability within the maintenance team. This position is part of the maintenance team and is expected to operate as a hands-on contributor, actively supporting daily plant operations. The role will work side-by-side with maintenance technicians on the floor, including troubleshooting equipment issues and occasionally performing mechanical and electrical work as needed to support uptime.

Primary Responsibilities:

• Report to work as scheduled every day, and demonstrate great attendance.
• Troubleshoot and resolve electrical and controls-related issues to minimize downtime and support production needs.
• Own and support all plant control systems, including PLCs, HMIs, VFDs, and SCADA systems.
• Actively support the maintenance team on the floor as part of daily operations.
• Occasionally perform mechanical and electrical work ("turn a wrench") to support uptime and team effectiveness.
• Develop, modify, and optimize PLC and HMI programs to improve equipment performance, reliability, and efficiency.
• Support and lead controls integration for new equipment and capital projects, including:
• Factory Acceptance Testing (FAT) and Site Acceptance Testing (SAT)
• Startup and commissioning support
• System validation and performance optimization
• Standardize controls architecture and documentation across the plant.
• Maintain and update electrical schematics, network layouts, and controls documentation.
• Partner with OEMs (e.g., ovens, packaging systems) to support troubleshooting, upgrades, and system improvements.
• Ensure proper backup and version control of all PLC and HMI programs.
• Support plant network related to controls systems (OT network), ensuring secure and reliable connectivity.
• Identify and implement automation improvements to reduce labor, improve throughput, and enhance product quality.
• Support root cause analysis (RCA) efforts for recurring downtime and implement permanent corrective actions.
• Train and support maintenance technicians in basic controls troubleshooting and system understanding.
• Collaborate with maintenance and operations teams to ensure equipment readiness and minimal disruption to production.
• Ensure all controls systems comply with safety standards, GMPs, and food safety requirements.
• Support integration of systems with ERP/plant systems (e.g., Plex) where applicable.
• Drive continuous improvement initiatives related to automation, controls, and system performance.
• Perform other duties as assigned or of a similar nature or level.

Qualifications:

• Bachelor's degree or equivalent experience required (Electrical Engineering, Controls Engineering, or related field preferred).
• 5+ years of experience in controls engineering within a manufacturing environment (food/CPG preferred).
• Strong experience with PLC programming (Allen-Bradley/Rockwell strongly preferred).
• Experience with HMI and SCADA systems (FactoryTalk, Wonderware, or similar).
• Strong knowledge of: Industrial networks (Ethernet/IP, Modbus, etc.). Drives (VFDs), motors, and electrical systems.
• Troubleshooting electrical and automation systems in a live production environment.
• Demonstrated hands-on experience supporting maintenance teams, including mechanical and electrical troubleshooting.
• Experience supporting capital projects, including equipment installation and commissioning.
• Ability to read and interpret electrical schematics and technical drawings.
• Experience working with OEM equipment and vendors.
• Familiarity with food safety, GMP, and regulated manufacturing environments.
• Experience with ERP systems (Plex experience a plus).
• Proficient in Microsoft Office Suite.
• Strong problem-solving and analytical skills.
• Ability to manage multiple priorities in a fast-paced environment.
• Strong communication skills across technical and non-technical teams.
• High sense of urgency and accountability.
• Ability to train and develop maintenance personnel on controls systems.

Position Type/Expected Hours of Work:

This is a Full Time Exempt 40 hour per week position, and it may require working additional hours depending on the needs of the business. TRAVEL: This position may require minimal travel.