What You Will DoThe
Controls Engineer is a
data-driven systems specialist who leverages deep PLC expertise to identify performance trends, optimize system throughput, and provide 'surgical' technical leadership. This role combines emergency troubleshooting with long-term performance engineering, using data analysis tools such as Grafana and Looker, as well as LLMs, to solve problems and enhance site performance.
This role combines
deep controls engineering expertise with
front-line operational ownership, providing escalation-level troubleshooting, safe modification of PLC code, system optimization through data analysis, and mentorship of Senior and Maintenance Engineers.
The position is
not purely desk-based: the successful candidate must be comfortable working on live systems, responding to critical incidents, and occasionally supporting operations at night and on weekends.
Key Responsibilities1. Controls Engineering & Troubleshooting- Provide front-line and escalation support for live production control systems (PLC, SCADA, HMI, Safety PLCs)
- Diagnose and resolve complex hardware and software faults using:
- SCADA/HMI diagnostics
- PLC code monitoring and modification (Siemens TIA Portal preferred)
- Industrial networks (e.g. Profinet, CAN bus, barcode readers)
- Implement temporary workarounds or controlled PLC changes to safely maintain operations when required.
- Ensure all changes follow change control, backup, and documentation standards.
2. Safety & Compliance- Perform troubleshooting and system modifications in line with electrical safety and machine safety standards.
- Maintain and troubleshoot Safety PLC systems, including interlocks, door sensors, and safety devices.
- Promote a strong safety-first culture, including incident prevention and safe response during high-risk activities
3. Execution & Operational Excellence- Respond rapidly to system failures with appropriate urgency
- Drive efficient resolution while ensuring long-term reliability (not just "quick fixes")
- Collaborate with inventory teams to manage critical spare parts and minimize downtime
- Support planned maintenance and quality inspections across the site.
4. Data Analysis & System Performance- Use operational KPIs (uptime/downtime, DPTOs, EPTIs, PM data, reactive events) to identify trends and weaknesses.
- Propose and implement data-driven system optimizations to improve throughput, reliability, and stability.
- Analyze complex datasets using Grafana and Looker to identify problems and systemic inefficiencies outside standard maintenance loops.
- Produce clear Root Cause Analyses (RCAs) and performance reports for stakeholders
- Lead Operational Improvement projects
5. Communication, Documentation & Stakeholder Management- Communicate clearly with Engineering Managers, Operations, SMEs, CoE, and Systems Delivery teams
- Translate technical system behavior into actionable KPIs for site leadership, 'telling the story' of site performance through data.
- Own the Jira pipeline for controls-related improvements, ensuring external escalations are prioritized based on ROI and operational impact.
- Maintain high-quality documentation:
- Work orders and tickets
- PLC backups and version control
- Electrical diagrams and machine documentation
6. Leadership, Mentoring & Continuous Improvement- Act as a technical mentor to Senior and Maintenance Engineers
- Support upskilling programs and knowledge transfer
- Proactively identify recurring issues and recommend preventative or design improvements
- Stay current with new tools, technologies, and best practices in automation and controls
7. What Success Looks Like in this Role:- After 6 months, you aren't just reacting to alarms; you are predicting failures before they happen using trend analysis.
- You have become the 'technical translator' for the SEOM (Site Engineering Operations Manager), turning system logs into a clear roadmap of site improvements.
- The Maintenance teams are more effective because you have turned your findings into 'Best Practice' SOPs.
Qualifications & ExperienceRequired - * Associate's (bachelor's preferred) degree in Electrical Engineering (or related discipline) or equivalent experience
- 5+ years in automation/controls roles, with 3+ years in a warehouse, distribution, or industrial environment
- Strong hands-on experience with:
- PLC systems (Siemens TIA Portal preferred)
- SCADA and HMI platforms
- Industrial automation hardware
- Control system communication protocols (WCS/WMS integration)
- Available for night and weekend work on an as-needed basis, in person or on call
- Strong analytical, problem-solving, and decision-making skills
- Desired knowledge on diagnosing, troubleshooting, and repairing printed circuit boards, using tools like soldering irons, oscilloscopes, and microscopes.
This role will require flexibility due to us being a 24/7 operation
What do I get in Return 401k Plan; 100% match up to 5% of earnings; Paid Vacation and Sick Days; 10 Paid Public Holidays; Medical, Dental, and Vision Insurance; Medical and Dependent Care; Flexible Spending Accounts Health Reimbursement Account; Company Contribution of 50% of Annual Deductible; Company Paid Life Insurance; Short and Long Term Disability Insurance; Employee Assistance Program
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