Controls Engineer

Controls Engineer

The Controls Engineer leads complex engineering projects that focus on motion systems, automation integration, process controls, material handling, and measurement system integration. This role designs and implements PLC-based machine and motion control systems, develops advanced control architectures, and deploys process and automation controls on a global scale. The Controls Engineer plays a key role in dramatically improving manufacturing productivity, enhancing process capability, and ensuring seamless technology transfer from development to production while meeting stringent safety and performance standards.

Responsibilities:

• Lead engineering projects focused on motion systems, automation integration, process controls, material handling, and periodic measurement system integrations.
• Design, program, and implement PLC-based machine and motion control systems, system integration, sensors, electro-mechanical devices, and robotics.
• Oversee and lead the implementation of hardware for control and safety systems to ensure reliable and compliant operation.
• Interface with external system integrators and machine builders to deliver fully integrated process equipment systems to manufacturing plants on time, within budget, and in line with performance requirements.
• Drive significant productivity gains through innovative control software and hardware design implementations.
• Develop and improve manufacturing system capabilities for seamless part tracking, measurements, process control, and data analysis using SCADA systems.
• Lead the development and deployment of process and automation controls on a global scale to support multiple manufacturing locations.
• Report on project activities on a predetermined basis, ensuring results meet customer requirements and applicable national and international equipment safety standards.
• Mentor colleagues and promote best practices in controls development, documentation, and implementation.
• Participate in the development of control architectures, functional specifications, design and test plans, and system integration requirements that meet process, manufacturing, and customer needs.
• Coordinate closely with manufacturing teams to ensure smooth transfer of technology from development to production environments.
• Liaise with quality, process, and metrology teams to support continuous improvement initiatives and maintain customer compliance.
• Lead obsolescence projects aimed at increasing fundamental process capability within the division controls function.
• Collaborate closely with process, quality, and measurement functions to ensure robust and reliable manufacturing systems.
• Design and implement industrial communication technologies such as Ethernet/IP, EtherCAT, and Profinet to support integrated automation solutions.
• Work collaboratively with R&D teams to explore new technologies, drive continuous improvement, and support advanced measurement and image processing systems.
• Apply project management skills to scope projects, develop budgets, define timelines, and manage execution using tools such as MS Project.
• Lead technical teams as part of larger capital or automation projects, ensuring alignment with project objectives and timelines.
• Support equipment engineering, process debugging, and troubleshooting activities to maintain high levels of operational performance.
• Contribute to the integration of robots, machine vision systems, MES integration, SPC, and industrial software development into manufacturing environments.

Essential Skills:

• 7-10 years of experience in industrial controls, with a proven track record of leading projects in automation, process controls, and motion systems.
• Bachelors degree in Computer Engineering, Electrical Engineering, or Electrical Engineering Technology, with a minimum of 5 years of hands-on experience.
• Strong experience designing and programming PLC systems, primarily Rockwell, Siemens, and Omron.
• Hands-on experience with HMI and SCADA systems, including FT View, Optix, Ignition, and iFix.
• Solid understanding of electrical engineering principles and their application to control and automation systems.
• Capability to design, develop, and deliver fully integrated machine and motion control, automation, and process machine systems to manufacturing environments.
• Familiarity with logic-based programming and IEC-based PLC programming structures, including ladder logic, function blocks, structured text, and sequential flowcharts.
• Proven experience transferring technology from development to manufacturing environments, ensuring seamless integration and operational success.
• Strong analytical and problem-solving skills, with the ability to troubleshoot and resolve technical issues efficiently.
• Excellent verbal and written communication skills, with the ability to effectively document processes and present technical information to diverse audiences.
• Experience designing and implementing industrial communication technologies such as Ethernet/IP, EtherCAT, and Profinet.
• Strong organizational skills with the ability to manage multiple projects and priorities.
• Independent thinking and technical curiosity, with a proactive approach to identifying and solving engineering challenges.
• Interpersonal skills that support engaging, enabling, and open collaboration with cross-functional teams.
• Adaptability and flexibility in adjusting to changing project demands, technologies, and global deployment requirements.

Additional Skills & Qualifications:

• Knowledge of programming languages such as C, C#, Python, HTML, and MATLAB for automation, data analysis, and industrial software development.
• Experience working collaboratively with R&D teams to explore new technologies and drive continuous improvement in manufacturing and measurement systems.
• Knowledge of algorithms for measurements and image processing systems, including machine vision applications.
• Project management skills, including scoping, budgeting, timeline development, and use of tools such as MS Project.
• Experience with equipment engineering, process support, and debug activities in a manufacturing environment.
• Ability to lead technical teams as part of larger capital or automation projects.
• Familiarity with Fanuc and ABB robot programming and integration into automated manufacturing systems.
• Experience with robot integration, machine vision systems, MES integration, SPC, and industrial software development.
• Exposure to capital project management and large-scale automation initiatives.
• Strong problem-solving mindset with the ability to identify and resolve challenges efficiently.
• Demonstrated ability to adapt to new technologies and evolving project requirements.
• Technical curiosity and a continuous improvement orientation that supports innovation in controls and automation.

Work Environment:

This role is based in Harrodsburg, KY and supports manufacturing operations in a dynamic, growth-oriented environment. The position involves 30-40% domestic and international travel, with trips typically ranging from one day to several weeks, to support global deployment of automation and process controls and collaboration with plant and project teams. The standard work schedule is approximately 40 hours per week, with the expectation to work the hours required to successfully deliver project objectives and support operational requirements. The work environment centers on advanced manufacturing technologies, including PLCs (Rockwell, Siemens, Omron), HMI and SCADA platforms (FT View, Optix, Ignition, iFix), industrial communication networks (Ethernet/IP, EtherCAT, Profinet), robotics (Fanuc, ABB), machine vision systems, MES integration, and SPC tools. The culture emphasizes technical excellence, continuous improvement, and cross-functional collaboration among process, quality, measurement, and R&D teams, offering the opportunity to contribute to significant growth across multiple product lines and to work with cutting-edge optical and automation technologies.

Job Type & Location:

This is a Permanent position based out of Lexington, KY.

Pay and Benefits:

The pay range for this position is $105,000.00 - $145,000.00/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.

Company-wide bonuses and long-term incentives align with key business results and ensure you are rewarded when the company performs well. As part of our commitment to your financial well-being, we provide a 100% company-paid pension benefit with fixed contributions that grow throughout your career. Combined with matching contributions to your 401(k) savings plan, Corning’s total contributions to your retirement accounts can reach between 7% and 12% of your pay, depending on your age and years of service. Our health and well-being benefits include medical, dental, vision, paid parental leave, family building support, fitness, company-paid life insurance, disability, disease management programs, paid time off, and an Employee Assistance Program (EAP) to support you and your family. Getting paid for our work is important, but feeling appreciated and recognized for those contributions motivates us much more. That’s why we offer a recognition program to celebrate successes and reward colleagues who make exceptional contributions.

Workplace Type:

This is a fully onsite position in Lexington, KY.

Application Deadline:

This position is anticipated to close on Oct 20,