Controls Engineer

General Job Function:

The Controls Engineer is responsible for designs, installs, optimizes, and adapts electronic control systems and instruments to automate and monitor industrial processes. This role focuses on developing technical designs, process diagrams, SCADA block diagrams, and control schematics to implement automation controls. The incumbent will configure systems using PLC and HMI techniques, as well as model, test, and measure output and data to analyze performance or quality issues and develop solutions to ensure optimal performance and minimal downtime of roll-form equipment.

Job Duties:

• Exercises independent judgment in diagnosing electrical control failures, including sensors, actuators, and networked control components, determining corrective actions, and implementing modifications to maintain optimal production efficiency.
• Support the engineering design and development of electrical control systems and devices.
• Assists with testing systems, devices, and instruments. Documents testing procedures, measures performance results, and records them following established methods.
• Troubleshoot and respond to quality issues, machine, and system failures, adjust, repair, maintain, and rebuild roll form machinery and ancillary equipment throughout the plant.
• Perform routine and preventive maintenance to ensure the machine and equipment can produce quality parts safely and efficiently.
• Interface with PLCs (e.g., Allen-Bradley, Siemens) for troubleshooting, online diagnostics, and minor logic modifications.
• Ensure compliance with OSHA, NEC, and internal safety policies.
• Maintain accurate documentation of electrical configurations, equipment changes, and maintenance records.
• Assist in the assembly, programming, and installation of equipment as necessary.
• Provide training to internal personnel as necessary.
• Performs other incidental and related duties as required and assigned, including projects or assignments to support the company.

Working Conditions:

• The Controls Engineer is a safety-sensitive position working directly with machinery and equipment—frequent exposure to a non-climate-controlled manufacturing environment where ambient air temperature occasionally exceeds outside air temperature.
• Must be able to bend at the waist and knees, walk, and stand for extended periods.
• Must be able to lift and move objects weighing up to 50 pounds when necessary.
• Must be able to bend, stoop, crawl under or over, and frequently climb stairs.
• Specific vision abilities required by this job include close vision, distance vision, peripheral vision, and the ability to adjust focus.
• Capable of working in confined spaces and off the ground with height variances.
• Must be available to work overtime, including weekends, to meet the organization's needs.

Required Education, Experience & Skills:

• Bachelor's degree in Electrical Engineering Technology or related field, or 2+ years of equivalent technical experience.
• Hands-on electrical, mechanical, hydraulic, and pneumatic experience in a roll forming or metal stamping manufacturing environment preferred
• Hands-on experience with PLC troubleshooting and interfacing.
• Working knowledge of industrial electrical systems, including 3-phase power, control wiring, and safety circuits.
• Familiarity with VFDs, relays, sensors, HMIs, and Ethernet-based control networks.
• Must be computer literate and proficient with Windows and MS Office (Word, Excel, and PowerPoint).
• Demonstrated ability to read and interpret electrical and hydraulic schematics, blueprints, technical procedures, safety rules, operating instructions, and procedure manuals.
• Ability to work with and communicate (verbal and written) effectively within all levels of the organization.
• Ability to add, subtract, multiply, and divide inches and pounds using whole numbers, common fractions, and decimals.
• Ability to self-motivate, problem-solve, and work in a dynamic environment.
• Ability to apply common sense understanding to complete written, oral, or diagram instructions.