We seek a skilled Controls Engineer to lead automation, digital integration, and technical support in our manufacturing operations. The ideal candidate excels in PLC programming, MES/ERP connectivity, robotics, Industry 4.0 technologies, and enterprise software support (SigmaNEST and SimTrans). This role requires both hands-on execution and strategic planning for digital transformation initiatives while also serving as a technical support resource for critical manufacturing systems.
Deliverables & Responsibilities:
Automation & Controls:
- Design, program, and troubleshoot PLC-based control systems (Allen-Bradley, Siemens, etc.) for new equipment and retrofit projects.
- Create and maintain electrical schematics, panel layouts, and wiring diagrams using AutoCAD Electrical or EPLAN.
- Develop modular, scalable code structures for efficient reuse and system flexibility.
- Architect and implement data bridges between shop floor equipment, MES, and ERP systems (SAP, Oracle, Plex, etc.).
- Standardize data structures and communication protocols using OPC UA, MQTT, and REST APIs.
- Program and commission industrial robots (Fanuc, ABB, Motoman) for applications including material handling, assembly, and inspection.
- Integrate robotics with safety systems, vision systems, and control architecture.
- Lead deployment of IoT-enabled devices for asset monitoring, predictive maintenance, and real-time analytics.
- Implement edge computing solutions for latency-critical operations and data reduction strategies.
- Collaborate with IT/OT teams to ensure secure, scalable industrial network architecture.
- Champion Industry 4.0 concepts: digital twins, virtual commissioning, machine learning integration, and data lakes.
- Evaluate and implement smart sensors and intelligent devices for condition-based monitoring and self-diagnostics.
- Ensure compliance with industrial cybersecurity frameworks (ISA/IEC 62443, NIST).
- Provide first-line technical support for SigmaNEST nesting software and SimTrans integration across manufacturing sites.
- Troubleshoot license pool/seat issues, configuration errors, and connectivity between SigmaNEST, SimTrans, and Oracle Fusion.
- Maintain system stability by monitoring logs, diagnosing failures, and coordinating fixes with IT and vendor support teams.
- Train engineers, planners, and operators on best practices for using SigmaNEST and SimTrans to minimize downtime.
- Develop and update user documentation, FAQs, and troubleshooting guides.
- Write comprehensive specification sheets, RFQs, and technical documentation to guide machine selection and standardization.
- Develop control standards and glossary documentation to ensure consistency across global operations.
- Manage the full lifecycle of controls projects including design, procurement, FAT, installation, commissioning, and validation.
- Collaborate cross-functionally with mechanical, IT, safety, and manufacturing engineering teams to ensure seamless integration.
- Education:
- Bachelor’s degree in electrical engineering, Mechatronics, or related field.
- Experience:
- Minimum 7 years of experience in Controls/Systems Engineering and automation within a manufacturing environment.
- Strong proficiency in PLC/HMI programming, particularly Rockwell, Siemens, or Beckhoff.
- Experience with MES/ERP system integration and industrial communication protocols (Ethernet/IP, Modbus TCP, OPC-UA).
- Demonstrated hands-on experience in robotics programming and commissioning (Fanuc, ABB, or Motoman).
- Proven capability in machine installation, troubleshooting, and commissioning.
- Knowledge of IIoT platforms, industrial cybersecurity, and edge computing architectures.
- Familiarity with digital twin modeling, SCADA systems, and cloud integration (AWS, Azure IoT, etc.) is a plus.
- Excellent problem-solving skills and ability to work in a high-mix, fast-paced environment.
