Job Description

The Automation Controls Engineer provides hands-on technical leadership and controls engineering expertise for robotics, automation, and manufacturing systems while coordinating daily activities to support safe, reliable, and efficient production. This role serves as the primary point of contact for automation and controls priorities, communicates critical issues, and promotes effective collaboration among automation and robotics technicians, maintenance, engineering, operations, and supervision.

Success is measured through disciplined safety and LOTO practices, timely communication, project execution, and shared accountability for OEE, scrap, equipment reliability, and safety compliance.

The expected annual salary range for this role is $77,000 - $126,000 a year depending on experience. This position is also eligible for a variable incentive program.

Design, Development & Implementation

• Develop automation and controls concepts based on process requirements, manufacturing standards, and design guidelines
• Design, develop, test, and implement PLC, HMI, SCADA, motion control, and data acquisition software using Beckhoff TwinCAT and Allen-Bradley Studio 5000 platforms
• Review equipment and production concepts including safety risk assessment, mechanical design, electrical controls, robotics, vision, and industrial communications
• Select, evaluate, and integrate automation components, controls hardware, sensors, actuators, safety devices, and robotic systems (Staubli, Universal Robots, Epson)
• Support FAT, SAT, commissioning, and production release of new equipment; coordinate line moves, installations, and project handoffs

Operations, Maintenance & Troubleshooting

• Develop and maintain PLC software, HMI screens, control logic, machine diagnostics, and system alarms for new and existing equipment
• Configure and support industrial networks (EtherCAT, Ethernet/IP, Profinet, Modbus TCP) and troubleshoot servo drives, VFDs, motion systems, and safety PLCs
• Diagnose and resolve mechanical, pneumatic, electrical, communication, and control-system issues to minimize downtime
• Perform preventive maintenance including calibration, lubrication, testing, validation, and safety checks
• Lead root cause analysis and implement corrective actions to reduce repeat failures and improve MTTR, MTBF, and equipment reliability

Production Support & Continuous Improvement

• Serve as escalation point for production support and prioritize issues based on safety, quality, and production impact
• Analyze downtime, scrap, cycle time, and OEE data to identify improvement opportunities and lead efforts to meet production goals
• Support integration and optimization of AMR/AGV systems, vision systems, and automation controls
• Create and maintain automation dashboards and data visualization tools for decision-making
• Evaluate new technologies including AI-enhanced vision, advanced safeguarding, and Industry 4.0 solutions to enhance production capability and reliability

Training, Mentoring & Subject Matter Expertise

• Execute automation, robotics, and controls training based on qualification requirements
• Mentor and train technical personnel on machine maintenance, controls troubleshooting, robotics, safety, and diagnostic techniques
• Act as automation and controls subject matter expert by providing advanced troubleshooting guidance and developing troubleshooting guides and training materials
• Participate in on-call rotation supporting robotics, automation, and controls functions

Qualifications

WHAT YOU BRING TO THE ROLE
• Bachelor's degree in Electrical Engineering, Controls Engineering, Automation Engineering, Mechatronics, or related engineering field
• Exposure to programming, troubleshooting, and supporting PLC-based manufacturing equipment
• Knowledge of Beckhoff TwinCAT and/or Allen-Bradley Studio 5000 platforms or related PLC
• Ability to understand, install, troubleshoot, and document motor controls, industrial networks, sensors, pneumatics, and safety circuits
• Strong electronics, electrical, mechanical, and pneumatic troubleshooting capability
• Ability to read electrical schematics, mechanical drawings, controls documentation, and programming documentation
• Strong time management skills with ability to manage multiple priorities, people, and production demands
• Clear communication skills and ability to collaborate with maintenance, engineering, production, suppliers, and management

• Legal authorization to work in the U.S. is required. We will not sponsor individuals for employment visas now or in the future for this job posting.
• Relocation assistance is not offered for this position.

Physical Requirements and Work Environment:

• Ability to work on a manufacturing shopfloor environment
• Must wear company-provided ESD safety-toed shoes, smock, and other PPE in required areas
• Sitting or standing for 8+ hours, reaching, and using hands/fingers to operate a computer and other office equipment
• Must be able to push, pull, reach, twist, turn, stoop for duration of 8+ hour shifts
• Ability to lift or carry objects up to 40 lbs. unassisted
• Ability to climb ladders
• Ability to bend at waist and perform repetitive foot and hand action
• Dexterity of hands and fingers to operate any required computer keyboard, mouse, and other technical instruments.

ADDITIONAL WAYS TO STAND OUT
• 2+ years of experience programming, troubleshooting, and supporting PLC-based manufacturing equipment
• 2+ years of experience installing, teaching, maintaining, and troubleshooting robotic or automated systems
• Experience with vision systems, AMRs/AGVs, servo motion, safety PLCs, data collection, dashboards, and Industry 4.0 solutions
• Experience with automated storage and retrieval systems and controls.
• Experience leading technical teams, mentoring technicians, or coordinating controls portions of capital projects

Additional Information

All your information will be kept confidential according to EEO guidelines.