Controls Engineer - Medical Devices

Flex is the diversified manufacturing partner of choice that helps market-leading brands design, build and deliver innovative products that improve the world.A career at Flex offers the opportunity to make a difference and invest in your growth in a respectful, inclusive, and collaborative environment. If you are excited about a role but don't meet every bullet point, we encourage you to apply and join us to create the extraordinary.Job SummaryPosition SummaryThe Controls Engineer is responsible for the design, implementation, maintenance, troubleshooting, and continuous improvement of automated manufacturing equipment used in the production of medical devices. This role supports production uptime, equipment reliability, product quality, and regulatory compliance through the application of industrial automation technologies, including Allen-Bradley PLCs, FactoryTalk HMIs, OSI PI SCADA systems, and Cognex vision systems.The Controls Engineer works closely with Controls Technicians, Maintenance, Manufacturing Engineering, Quality, Validation, and Production teams to resolve equipment issues, execute automation improvement projects, and ensure manufacturing systems operate safely and efficiently.Key ResponsibilitiesAutomation System SupportProvide technical support for automated manufacturing equipment to maximize machine uptime and production efficiency.Troubleshoot and resolve issues involving Allen-Bradley PLCs, FactoryTalk HMIs, industrial networks, motion control systems, and field devices.Investigate recurring equipment faults and implement corrective actions to improve reliability.Support production during equipment failures, startup activities, and process disruptions.Assist in root cause analysis and develop sustainable solutions to prevent recurring issues.PLC and HMI DevelopmentDevelop, modify, test, and maintain PLC programs using Rockwell Studio 5000 and related software platforms.Design and improve FactoryTalk View SE/ME HMI applications to enhance operator usability and equipment diagnostics.Create and maintain PLC documentation, tag databases, alarm definitions, and system architecture drawings.Implement automation standards and best practices across manufacturing equipment.Continuous Improvement ProjectsLead and execute PLC and HMI improvement projects to enhance safety, reliability, throughput, and maintainability.Develop machine performance enhancements including:Improved fault diagnostics and alarm handlingCycle time reductionsAutomated data collectionEnhanced operator interfacesOEE improvement initiativesPredictive maintenance capabilitiesIdentify opportunities to modernize legacy controls systems and improve production efficiency.SCADA and Data SystemsSupport and maintain OSI PI data collection and visualization systems.Develop and manage equipment performance dashboards, production metrics, alarm monitoring, and operational reporting tools.Ensure accurate collection and storage of manufacturing data for quality, traceability, and operational analysis.Collaborate with Manufacturing Engineering and Operations teams to leverage process data for continuous improvement initiatives.Vision System IntegrationConfigure, troubleshoot, and optimize Cognex vision inspection systems used for product verification, quality assurance, and process control.Develop and maintain vision inspection programs and communication interfaces with PLCs and manufacturing equipment.Support validation and implementation of new vision inspection applications.Collaboration with Controls TechniciansWork closely with Controls Technicians to diagnose and resolve production equipment issues.Provide technical guidance and mentorship to Controls Technicians during troubleshooting and repair activities.Develop troubleshooting procedures, standard work, and training materials.Participate in shift support initiatives and escalation processes for critical manufacturing equipment.Review machine downtime events and partner with technicians to identify long-term corrective actions.Equipment Validation and ComplianceSupport equipment qualification, validation, and change control activities in accordance with medical device manufacturing requirements.Ensure automation systems comply with applicable regulatory standards, quality systems, and company procedures.Participate in risk assessments, FATs, SATs, IQ/OQ/PQ activities, and audit support.Documentation and Project ManagementMaintain detailed technical documentation including:PLC and HMI backupsElectrical drawingsNetwork architecture diagramsFunctional specificationsChange control recordsManage automation projects from concept through deployment and production support.Coordinate with vendors, integrators, and internal stakeholders on automation-related initiatives.Required QualificationsBachelor's degree in Electrical Engineering, Controls Engineering, Computer Engineering, or related technical discipline preferred, will consider controls related experience.3+ years of experience supporting automated manufacturing equipment.Experience with Allen-Bradley PLC platforms including:ControlLogixCompactLogixStudio 5000Experience with FactoryTalk View ME/SE HMI development.Experience with industrial Ethernet networks and communication protocols.Experience troubleshooting automation systems in a manufacturing environment.Strong understanding of electrical control systems, sensors, actuators, VFDs, and motion control systems.Preferred QualificationsExperience in medical device, pharmaceutical, biotechnology, or regulated manufacturing environments.Experience with OSI PI System or similar SCADA/data historian platforms.Experience with Cognex In-Sight or VisionPro vision systems.Familiarity with FDA regulations, GMP requirements, and validation processes.Experience with MES, SQL databases, data analytics, or Industry 4.0 initiatives.Knowledge of machine safety standards and risk assessment methodologies.Key CompetenciesPLC Programming and TroubleshootingHMI Development and OptimizationSCADA and Data Historian SystemsMachine Vision SystemsRoot Cause AnalysisContinuous ImprovementProject ManagementCross-Functional CollaborationTechnical DocumentationEquipment Reliability and Uptime ImprovementTraining and MentorshipMedical Device Manufacturing ComplianceJT05AA01 MS14 CC11 What you'll receive for the great work you provide:Full range of medical, dental, and vision plansLife InsuranceShort-term and Long-term DisabilityMatching 401(k) ContributionsVacation and Paid Sick TimeTuition Reimbursement Application Deadline:Applications for this job position will be accepted for at least five days following the job posting start date below and continuing until the end date below or until the position is filled. This posting may close sooner due to application volume.Job Posting Start Date 08-05-2026 Job Posting End Date 10-09-2026 Job CategoryProduction EngineeringIs Sponsorship Available?NoFlex is an Equal Opportunity Employer and employment selection decisions are based on merit, qualifications, and abilities. We do not discriminate based on: age, race, religion, color, sex, national origin, marital status, sexual orientation, gender identity, veteran status, disability, pregnancy status, or any other status protected by law. We're happy to provide reasonable accommodations to those with a disability for assistance in the application process. Please email View email address on click.appcast.io and we'll discuss your specific situation and next steps (NOTE: this email does not accept or consider resumes or applications. This is only for disability assistance. To be considered for a position at Flex, you must complete the application process first).SummaryLocation: USA, TX, AustinType: Full time