Job Overview:This role is aligned to the Coffee Operating UnitLocation: 3109 Plant Water Road, Knoxville, TN 37914
Shift & Schedule:This is a salaried position supporting a flexible schedule based on business needs. The role is expected to support operations across all shifts and is typically scheduled for four 10-hour days, Monday through Sunday. Hours and days may vary to support production priorities, continuous improvement initiatives, and project execution.
The
Senior Automation Controls Engineer serves as the site technical expert for automation, controls, and industrial systems, driving the reliability, optimization, and continuous improvement of automated manufacturing and material handling equipment. This role partners closely with Operations, Maintenance, Engineering, Quality, and IT to maximize equipment uptime, improve system performance, and support future automation initiatives.
The Senior Automation Controls Engineer will lead automation projects from concept through implementation, establish engineering standards, mentor technical teams, and leverage data-driven decision-making to improve safety, quality, and operational efficiency.
Key ResponsibilitiesAutomation & Controls Engineering- Serve as the site subject matter expert for PLCs, HMI/SCADA systems, industrial networks, motion control, robotics, drives, and automated equipment.
- Develop and maintain automation standards, control philosophies, and engineering best practices across the facility.
- Design, program, troubleshoot, and optimize PLC and HMI applications while supporting equipment upgrades and system enhancements.
- Partner with OEMs, system integrators, and vendors to commission new equipment and improve existing automation systems.
- Lead troubleshooting efforts for complex electrical, controls, instrumentation, and automation issues to minimize downtime.
- Evaluate emerging automation technologies and recommend improvements that increase reliability, throughput, and operational efficiency.
Reliability & Continuous Improvement- Drive equipment reliability through root cause analysis (RCCA), preventive maintenance, predictive maintenance, and continuous improvement initiatives.
- Analyze equipment performance, downtime trends, and system data to identify opportunities for improvement.
- Develop and maintain preventive maintenance strategies, standard operating procedures (SOPs), and troubleshooting documentation.
- Lead and participate in Kaizen events, TPM initiatives, 5S activities, and other Lean Manufacturing efforts.
- Support capital projects including equipment specification, design review, installation, startup, commissioning, and validation.
Leadership & Collaboration- Provide technical leadership and mentorship to maintenance technicians, controls technicians, and operations personnel.
- Train production and maintenance teams on new automation systems, controls, and equipment functionality.
- Partner cross-functionally with Operations, Maintenance, Engineering, Quality, IT, and external vendors to achieve site performance objectives.
- Support project planning, resource coordination, and execution while ensuring projects are completed safely, on time, and within budget.
Safety & Compliance- Champion a strong safety culture by ensuring compliance with OSHA regulations, Lockout/Tagout (LOTO), electrical safety standards, and company policies.
- Ensure automation systems comply with food safety, quality, and regulatory requirements.
- Participate in safety audits, risk assessments, and equipment safety reviews.
Data & Performance- Monitor and analyze key performance indicators including equipment uptime, OEE, fault history, and maintenance metrics.
- Utilize data analytics to identify trends, predict failures, and drive continuous improvement.
- Maintain accurate documentation including electrical drawings, PLC backups, network architecture, SOPs, and maintenance records.
Total Rewards:- Targeted annual compensation range of $85,000-$110,000.
- This is a salaried, exempt position paid biweekly. Compensation is competitive and commensurate with experience.
Benefits (Effective Day One, Where Applicable):
- Medical, Dental, and Vision Insurance
- Disability Coverage
- Paid Time Off (including vacation and sick leave)
- 401(k) with company match
- Tuition Reimbursement
- Mileage Reimbursement
Benefits are subject to eligibility requirements and applicable collective bargaining agreements.
Requirements:Education- Bachelor's degree in Electrical Engineering, Automation Engineering, Mechatronics, Industrial Engineering, or a related technical field preferred.
- High school diploma or GED required.
Experience- Minimum 7 years of experience supporting industrial automation and controls within a manufacturing, distribution, or automated material handling environment.
- Strong experience with Allen-Bradley PLC platforms (ControlLogix, CompactLogix), FactoryTalk, HMIs, VFDs, servo systems, and industrial networking.
- Experience troubleshooting electrical controls, instrumentation, robotics, vision systems, and automated equipment.
- Experience leading automation projects, system upgrades, and equipment commissioning.
- Strong understanding of preventive maintenance, root cause analysis, Lean Manufacturing, and TPM methodologies.
- Experience working with OEMs, system integrators, and cross-functional engineering teams.
Preferred Qualifications- Experience in high-speed manufacturing, food and beverage, consumer packaged goods, or automated distribution environments.
- Experience with SCADA systems, industrial Ethernet networks, SQL databases, and data historians.
- Knowledge of warehouse automation systems, conveyors, sortation systems, robotics, AGVs/AMRs, or ASRS equipment.
- Six Sigma Green Belt or Black Belt certification is a plus.
Physical Requirements / Working Conditions- Ability to lift, push, and pull up to 50 pounds as needed.
- Ability to walk production and warehouse floors for extended periods.
- Ability to climb ladders, access elevated platforms, bend, kneel, and work around energized industrial equipment while following established safety procedures.
- Ability to support off-shift, weekend, and emergency troubleshooting as business needs require.
