Sr Electrical Controls Engineer

Confidential Company  •  Middletown, OH

11 - 15 years experience  •  Manufacturing / Plastics

$100K - 120K
Posted on 10/19/17 by Kay Kennedy
Confidential Company
Middletown, OH
11 - 15 years experience
Manufacturing / Plastics
$100K - 120K
Posted on 10/19/17 Kay Kennedy

Company confidential is experiencing high growth...and we are adding many new roles!  If you have a passion for Motion Control Systems and HMI, love to design and implement new control systems for new product lines,  upgrade existing systems and are looking for a growing company with excellent career advancement potential....this might be the role for you! Makes this newly created role yours!


 The Sr Controls Engineer is responsible for the engineering, design, cost analysis, simulation, integration, programming, and troubleshooting of Programmable Logic Controllers (PLC), Process Automation Controllers (PAC), Human Machine Interfaces (HMI), Servo Systems, Robotics, and web handling controls for systems to support productivity and/or quality improvements for flexible packaging and conversion equipment. The Sr Electrical Controls Engineer will support and oversee facilities projects/needs, installation, projects, equipment repairs, and corporate initiatives as well as individually lead capital projects. Will support new products or features to help sales growth. This engineer will also ensure accuracy and completeness of associated technical documentation and supporttechnician training and development processes.


Essential Duties and Responsibilities: 

  • Provide Electrical & Controls Engineering design, modification, and support for multiple controls projects, ranging from a single machine to a complete line or process area.
  • Responsible for all Electrical & Controls programming, electrical schematics, and electricalengineering activities for new projects and/or equipment upgrades.
  • Possess extensive experiencewith various current flexible packaging conversion equipment technologies including but not limited to extrusion, printing, conversion, material handling. 
  • Coordinate, select, and execute design and programming of PLC, HMI, Servo Motion, and complex industrial projects from hardware and software integration through construction and commissioning for new and legacy equipment.
  • Provide ongoing direction for standardization of all future machines across all product lines for software, hardware, and programming. 
  • Capable of working in various programming platforms including Siemens, Beckhoff, and others. 
  • Directly involved with and capable of troubleshooting/design of programs in ladder logic and structured text, Codesys, C++, and other IEC 61131-3 standards
  • Provide hands on assistance for the Maintenance Department with installation, troubleshooting, and debugging equipment and systems. 
  • Provide support to R&D projects and special product trials for growth and customer needs. 
  • Prepare correspondence, reports, charts, presentations, and training as needed. 
  • Initiate and implement actions for continuous process improvement projects. 
  • Review on-going and future technologies to insure use of best available technology and practices.
  • Activities may be performed as Project Manager / Project Lead or in support of other Project Engineers efforts.
  • Assist with fulfilling the needs of the plant with respect to replacement of worn out or obsolete equipment, expansion of capacity to meet sales growth, equipment modification or replacement of packaging changes or cost reductions.
  • Management of the Capex process (Capital Acquisition Proposal), creation and tracking. 
  • Capable of specifying electrical factory infrastructure changes, upgrades, and documentation to support expansion and future growth. 
  • Coordination of third-party contractors during constructions phases of a project.
  • Perform on-site commissioning to implement and validate the system designs.
  • Provide appropriate technical documentation including a control sequence of operation, operational and maintenance manuals, and recommended spare parts lists to ensure that the design meets operations and maintenance customers’ needs.
  • Develop and maintain a progress schedule that meets project milestones.
  • Manage project prioritization and engineering process management including concept feasibility, engineering studies, and lead team design reviews.
  • Support and Manage Factory Acceptance Test (FAT) activities including samples and test material logistics and costs, team and vendor coordination, safety and quality risk assessments, punch lists, and validation processes through systems disposal.
  • Work simultaneously on multiple projects from concept to manufacturing acceptance in a collaborative team environment.
  • Coordinate and provide guidance to other engineers, operations, quality, maintenance, and scheduling departments, equipment suppliers, and contractors to ensure complete and timely design start-ups.
  • Complete all necessary documentation for machines (i.e. panel layouts, wiring diagrams, PLC programs, HMI programs, spare parts list, costed bill of materials, etc.)
  • Participate in protecting any intellectual property (i.e. patents, copyrights, etc.)


  • Must have excellent communication, planning, negotiation and organizational skills and the ability to independently manage a heavy workload.
  • Must have excellent project management experience and skill.
  • Must possess extensive experiencewith various current flexible packaging conversion equipment technologies including but not limited to extrusion, printing, conversion, material handling. 
  • Knowledge of common U.S., International Electrical Codes and Safety Codes and be compliant to their requirements
  • Must have experience in electrical drawing and BOM reading, generation, and checking
  • Must have excellent communication, planning, negotiation and organizational skills and the ability to independently manage a heavy workload. 
  • Have the judgment and experience to identify and evaluate cost and progress trends. 
  • Have the ability to develop and maintain competitive sourcing in regards to price and service. 
  • Receives input and coordination of information from various parties, and prepares and presents such information for management review.


Education and/or Experience                          

  • Bachelor’s or Master’s Degree in ElectricalEngineering, Computer Science or Computer Engineering from an accredited college/university or equivalent experience is preferred. 
  • 10+ years in organizational engineering efforts of a mid to large size company. 
  • System integration and data collection across multiple platforms.
  • Experience in the protective packaging industry a plus


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