We are seeking an experienced Senior Controls Engineer with 5–10 years of direct, hands-on experience programming, troubleshooting, maintaining, and improving automated manufacturing equipment and industrial control systems.

This individual will be responsible for ensuring manufacturing equipment operates safely, efficiently, and reliably through the development, modification, and troubleshooting of PLC programs, HMI systems, and electrical controls.

The ideal candidate will have a strong background in Rockwell/Allen-Bradley PLC programming, HMI troubleshooting, industrial automation, and electrical control systems, along with extensive experience working directly with manufacturing equipment. Experience in a packaging facility is a plus.

Candidates must have professional experience working as a Controls Engineer and independently performing PLC programming, HMI troubleshooting, and industrial automation responsibilities. Academic experience or general exposure to controls systems alone will not qualify.

Key Responsibilities

PLC Programming & Industrial Automation

Program, modify, and troubleshoot PLC systems, particularly Rockwell/Allen-Bradley platforms.
Diagnose and resolve PLC programming issues affecting manufacturing equipment.
Develop and implement automation improvements to increase equipment efficiency and reliability.
Support the integration, installation, and commissioning of automated manufacturing equipment.

HMI Systems & Electrical Controls

Program, configure, and troubleshoot HMI systems used in manufacturing operations.
Diagnose electrical control system failures and automation-related equipment issues.
Read, interpret, and modify electrical schematics and control diagrams.
Troubleshoot sensors, motors, variable frequency drives (VFDs), and other industrial control components.
Resolve communication issues between PLCs, HMIs, and automated equipment.

Manufacturing Support & Process Improvement

Provide hands-on controls engineering support for manufacturing equipment and production systems.
Troubleshoot equipment failures and implement corrective actions to minimize downtime.
Identify opportunities to improve manufacturing automation, equipment performance, and operational efficiency.
Collaborate with maintenance, engineering, and production teams to resolve complex technical issues.
Support controls engineering projects from design and programming through implementation and testing.

Required Qualifications

Education

Bachelor's degree in Electrical Engineering, Mechanical Engineering, Controls Engineering, Automation Engineering, or a related engineering discipline.

Professional Experience

5–10 years of direct professional experience as a Controls Engineer in an industrial manufacturing or automation environment.
Demonstrated hands-on experience programming, modifying, and troubleshooting PLC systems.
Professional experience working with Rockwell/Allen-Bradley PLCs and associated programming software.
Direct experience troubleshooting and modifying HMI systems.
Experience diagnosing electrical control systems and automated manufacturing equipment.
Proven ability to independently troubleshoot complex automation and controls issues.
Experience reading and interpreting electrical schematics and control diagrams.
Experience implementing automation improvements within a manufacturing environment.

Technical Skills

Rockwell/Allen-Bradley PLC programming
Studio 5000 / RSLogix
HMI programming and troubleshooting
Industrial automation and electrical controls
Electrical schematics and control panel troubleshooting
Sensors, motors, VFDs, and industrial equipment
Manufacturing equipment troubleshooting
PLC/HMI communication and system integration