Job Title: Controls Engineer Job Description This role designs, programs, and commissions advanced automation and control systems for complex manufacturing, material handling, and process applications. The Controls Engineer develops PLC and HMI/SCADA solutions on the Allen-Bradley Logix platform, integrates motion, safety, and third-party equipment, and supports full project lifecycles from system architecture through startup and documentation.
The position offers opportunities to work on diverse automation projects, collaborate with cross-functional teams, and contribute to high-performance industrial systems. Responsibilities Design, develop, and deploy comprehensive PLC programs using the Allen-Bradley Logix platform, including Studio 5000 and RSLogix 5000. Develop, configure, and maintain HMI and SCADA applications to support operator interfaces and supervisory control.
Program and commission high-speed, multi-axis synchronized motion systems using Kinetix servo drives, virtual master axes, electronic gearing, and camming for precision manufacturing operations. Design, program, and optimize complex conveyor and material handling systems, including accumulation conveyors, sortation systems, palletizers, and handoffs with automated guided vehicles (AGVs) or autonomous mobile robots.
Implement tracking, merging, diverting, and barcode or RFID scanning logic to ensure seamless product flow through high-throughput logistics and production lines. Design and optimize control strategies for web handling applications, including tension control, winding and unwinding, and registration for continuous weblines. Engineer control algorithms for extrusion processes, ensuring precise temperature regulation, pressure control, and line speed synchronization.
Implement complex batch process sequences in alignment with industry standards such as ISA-88. Design, tune, and troubleshoot advanced PID control loops, including cascade loops, ratio control, and feed-forward strategies to minimize disturbances and maximize process stability. Integrate third-party equipment, robotics, instrumentation, and vision systems into the primary control network using industrial communication protocols such as EtherNet/IP, ControlNet, and DeviceNet.
Plan and execute rigorous factory acceptance testing (FAT) and site acceptance testing (SAT), including system debugging, troubleshooting, and on-site commissioning. Design and implement hardware and software safety systems using Allen-Bradley GuardLogix controllers and safety-rated components in compliance with relevant safety standards such as ISO and ANSI B11.19. Create and maintain detailed engineering documentation, including functional design specifications, control philosophy documents, I/O lists, cause-and-effect matrices, and fully commented as-built code.
Collaborate with cross-functional teams, vendors, and customers to clarify requirements, resolve issues, and ensure successful project delivery. Lead or support projects in high-pressure manufacturing environments, ensuring systems meet performance, reliability, and safety expectations. Essential Skills Bachelor’s degree in Electrical Engineering, Mechanical Engineering, Computer Engineering, or a related technical discipline, or equivalent practical experience.
Minimum of 8–10+ years of hands-on controls engineering experience in a manufacturing, machinery builder (OEM), or heavy industrial process environment. Expert-level proficiency with Allen-Bradley hardware and software ecosystems, including ControlLogix, GuardLogix, Studio 5000, PanelView Plus, and FactoryTalk View SE/ME. Proven experience in PLC programming for Allen-Bradley platforms, including development, troubleshooting, and optimization.
Demonstrated mastery of high-speed motion control and multi-axis coordination using Kinetix servo drives and related motion technologies. Direct experience with continuous web handling lines, including tension control, winding and unwinding, and registratio