Controls Engineer-Manufacturing Automation

Job Title : Controls Engineer Manufacturing Automation (1st Shift Support)

Location : Indiana (Onsite)

Duration : 6 12 Months

Employment Type : W2 Contract

Pay Rate : $40 per hour on W2 (DOE)

Job Summary:

We are seeking an experienced Controls Engineer to support, troubleshoot, maintain, and optimize automated manufacturing systems in a fast-paced production environment. The ideal candidate will have hands-on experience with Allen-Bradley PLCs, industrial robotics, HMI systems, motion control, servo drives, industrial communication networks, and machine safety systems.

The Controls Engineer will collaborate with manufacturing, maintenance, and engineering teams to minimize equipment downtime, improve production efficiency, enhance system reliability, and support continuous improvement initiatives. This position primarily supports first-shift manufacturing operations at the facility in Indiana.

Key Responsibilities:

1. PLC Programming and Automation Controls

• Troubleshoot, maintain, modify, and optimize Allen-Bradley PLC systems, including PLC-5, CompactLogix, and ControlLogix.
• Develop, debug, and maintain PLC programs using Ladder Logic and Structured Text in accordance with IEC 61131-3 programming principles.
• Maintain PLC software, configuration files, backups, version control, and technical documentation.
• Develop structured, reusable, maintainable, and well-documented automation solutions.

1. HMI and Motion Control Systems

• Troubleshoot and optimize Human Machine Interface (HMI) applications to improve operator efficiency and machine performance.
• Diagnose, program, and troubleshoot Variable Frequency Drives (VFDs), servo drives, and Kinetix motion control systems.
• Tune motion control systems to reduce vibration, noise, positioning errors, and operational issues.
• Improve machine performance, cycle times, and equipment reliability.

1. Robotics and Machine Vision

• Program, troubleshoot, and maintain industrial robotic systems, preferably ABB and FANUC platforms.
• Diagnose robotic cell failures, end-of-arm tooling issues, and automation integration problems.
• Support machine vision systems through troubleshooting, calibration, tuning, and lighting adjustments.
• Ensure automated inspection systems operate reliably and meet production quality requirements.

1. Industrial Networks and Safety Systems

• Troubleshoot industrial communication networks and remote I/O systems, including EtherNet/IP, DeviceNet, and IO-Link.
• Support programmable safety controllers, safety logic, area scanners, light curtains, and related safety devices.
• Diagnose communication faults and control system integration issues.
• Help ensure manufacturing automation systems comply with applicable machine safety standards and site requirements.

1. Maintenance and Continuous Improvement

• Collaborate with manufacturing and maintenance teams to investigate equipment downtime and perform root-cause analysis.
• Develop and implement corrective and preventive actions to reduce recurring equipment failures.
• Document troubleshooting procedures, standardize solutions, and share technical lessons learned.
• Support capital projects, equipment upgrades, commissioning, and automation improvement initiatives.
• Assist with SCADA/MES interfaces and manufacturing data collection systems as required.

Job Requirements

Required Qualifications:

• Bachelor's degree in Electrical Engineering, Controls Engineering, Mechatronics Engineering, or a related technical discipline, or equivalent relevant industry experience.
• Advanced hands-on troubleshooting experience with Allen-Bradley PLC platforms, including PLC-5, CompactLogix, and ControlLogix.
• Strong knowledge of IEC 61131-3 programming principles, including Ladder Logic and Structured Text.
• Practical experience supporting manufacturing automation systems, including PLCs, HMIs, industrial networks, robotics, motion control, and SCADA/MES interfaces.
• Expertise in troubleshooting and tuning VFDs, servo drives, and motion control systems.
• Knowledge of EtherNet/IP, DeviceNet, IO-Link, and industrial remote I/O systems.
• Experience with programmable safety devices and industrial machine safety systems.
• Industrial robotics programming and troubleshooting experience, preferably with ABB and FANUC platforms.
• Strong analytical, problem-solving, and root-cause investigation skills.
• Excellent communication and collaboration skills when working with maintenance, operations, and engineering teams.
• Ability to work onsite in Lafayette, Indiana, and support first-shift manufacturing operations.

Preferred Qualifications

• Experience creating and updating electrical schematics using AutoCAD Electrical and/or EPLAN.
• CNC troubleshooting experience with Siemens, FANUC, or Mitsubishi controls.
• Experience in automotive, heavy equipment, machining, assembly, or high-volume manufacturing environments.
• Familiarity with SCADA, MES, and manufacturing data collection systems.
• Exposure to smart manufacturing, Industry 4.0, and digital transformation initiatives.
• Experience supporting equipment commissioning, production line upgrades, and automation deployments.

Work Environment and Schedule

• Onsite work in a manufacturing and production environment in Indiana.
• Primary support during first-shift operations.
• Occasional off-shift and on-call support may be required.
• Periodic travel may be necessary for equipment commissioning, troubleshooting, and deployment activities.

Candidate Submission Requirements

• Candidates must be able to independently participate in technical interviews and clearly explain their hands-on technical experience.
• Recent client references must be available and shared during the submission process.
• Candidates should be prepared to discuss relevant projects involving Allen-Bradley PLCs, robotics, motion control, industrial networks, and manufacturing automation troubleshooting.