The Controls Engineer is responsible for designing, implementing, and maintaining control systems across multiple production facilities to ensure optimal performance, reliability, and efficiency of manufacturing processes. This role provides technical expertise in automation, PLCs, robotics, and other control systems, while supporting continuous improvement initiatives and troubleshooting complex issues. To succeed, you need a strong background in controls engineering, project management, and cross-functional collaboration in a food manufacturing or similar environment.

• Design, program, and troubleshoot PLC (Programmable Logic Controller) systems, HMI (Human-Machine Interface) panels, and SCADA (Supervisory Control and Data Acquisition) systems.  

• Develop and implement control system solutions to improve production efficiency, product quality, and equipment reliability.  

• Lead the integration of new equipment and automation technologies into existing production lines.  

• Create and maintain electrical schematics, control system documentation, and standard operating procedures (SOPs).  

• Provide on-site and remote support to multiple production facilities to resolve control system issues and minimize downtime.  

• Diagnose and troubleshoot complex electrical, mechanical, and software-related problems in control systems.  

• Collaborate with maintenance, production, and engineering teams to identify root causes of equipment failures and implement corrective actions.  

• Conduct regular system audits to ensure control systems are operating efficiently and in compliance with safety and regulatory standards.  

• Manage controls-related projects, including scope definition, budgeting, scheduling, and resource allocation.  

• Coordinate with external vendors, contractors, and internal stakeholders to ensure timely and successful project completion.  

• Oversee the installation, commissioning, and validation of new control systems and equipment upgrades.  

• Ensure all projects adhere to food safety regulations (e.g., FDA, USDA, HACCP) and electrical standards (e.g., NFPA 70, NEC).  

• Identify opportunities to optimize control systems and processes through data analysis, automation, and advanced technologies.  

• Implement lean manufacturing principles and Six Sigma methodologies to drive operational excellence.  

• Stay updated on industry trends, emerging technologies, and best practices in controls engineering and automation.  

• Train maintenance and production staff on the operation, troubleshooting, and maintenance of control systems.  

• Develop training materials and conduct hands-on workshops to enhance technical skills across facilities.  

• Ensure all control systems comply with food safety regulations (e.g., GMP, HACCP) and electrical safety standards (e.g., OSHA, NFPA 70E).  

• Conduct risk assessments and implement safety measures to protect personnel and equipment.  

• Maintain accurate records of control system modifications, repairs, and compliance documentation.  

• Bachelor’s degree in Electrical Engineering, Controls Engineering, Automation, or a related field or equivalent experience

• 3+ years of experience in controls engineering, preferably in food manufacturing or a similar industry.  

• Proficiency in programming and troubleshooting PLCs (e.g., Allen-Bradley, Siemens), HMIs, and SCADA systems.  

• Strong knowledge of electrical systems, robotics, and industrial automation technologies.  

• Experience with project management, including budgeting, scheduling, and resource allocation.  

• Excellent problem-solving, analytical, and decision-making skills.  

• Strong communication and interpersonal skills, with the ability to work effectively across multiple facilities and teams.  

• Willingness to travel to support multiple production facilities as needed (up to 50% travel).  

• Professional Engineer (PE) license or equivalent certification.  

• Experience with food safety standards (e.g., FDA, USDA, HACCP) and regulatory requirements.  

• Knowledge of lean manufacturing and Six Sigma methodologies.  

• Familiarity with advanced manufacturing technologies, such as IIoT (Industrial Internet of Things) and machine learning.  

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