Controls Engineer

Position Overview

We are seeking a hands-on Controls Engineer to support the design, programming, integration, commissioning, and startup of industrial automation systems.

This position is ideal for a Controls Engineer who enjoys the integration side of automation — taking equipment from initial controls development through debug, installation, commissioning, and successful production startup.

The role will focus heavily on Allen-Bradley/Rockwell controls and FANUC robotics, with responsibility for integrating PLCs, HMIs, robotic systems, safety devices, vision systems, drives, sensors, and other automation equipment into complete manufacturing systems.

We are looking for someone who understands more than just PLC troubleshooting. The ideal candidate has experience developing controls systems, integrating equipment, debugging automated sequences, and bringing new machinery to life in a production environment.

Key Responsibilities

• Develop, program, modify, and troubleshoot Allen-Bradley PLC systems, including ControlLogix and CompactLogix platforms.

• Develop PLC applications using Studio 5000 / RSLogix 5000.

• Develop and modify HMI applications using FactoryTalk View and/or PanelView.

• Integrate FANUC robotic systems with Allen-Bradley PLC-controlled equipment.

• Establish and troubleshoot communication between PLCs, robots, HMIs, vision systems, drives, remote I/O, and other automation equipment.

• Develop and troubleshoot robot-to-PLC handshaking, I/O mapping, sequence logic, permissives, fault recovery, and automatic operating sequences.

• Configure and troubleshoot industrial communication networks, particularly EtherNet/IP.

• Support FANUC robot integration, including robot I/O, automated sequences, safety interfaces, and communication with PLC-controlled equipment.

• Perform controls development for automated assembly, material handling, robotic cells, conveyors, machine tending, and related manufacturing equipment.

• Develop and troubleshoot machine safety systems, including safety PLCs, emergency stops, light curtains, guarding, safety scanners, and related devices.

• Perform electrical and controls system debug during machine build and integration.

• Complete I/O checkout and verify field devices, sensors, actuators, motors, VFDs, pneumatic systems, and other machine components.

• Troubleshoot complex electrical, controls, communication, sequencing, and robotic issues.

• Support FAT, installation, commissioning, SAT, startup, and production launch activities.

• Travel to customer facilities to install, debug, commission, and launch automated equipment.

• Work directly with mechanical, electrical, robotics, manufacturing, and customer engineering teams during project execution.

• Diagnose issues during startup and implement software or controls changes necessary to achieve production requirements.

• Maintain controls documentation and support system handoff upon project completion.

• Read and interpret electrical schematics, controls drawings, I/O documentation, network architecture, and machine layouts.