Controls Engineer

Job Description: Controls Engineer / S.r Controls Engineer (Safety-Focused)

This role offers two distinct opportunities for experienced controls professionals. The Controls Engineer will focus on implementing and validating electric torque driver systems, including hardware selection, programming, and documentation. The Sr. Controls Engineer (Safety-Focused) will design, implement, and optimize medium to high complexity control and automation systems with a strong emphasis on functional safety, regulatory compliance, and technical leadership across production and development environments.

Responsibilities

• Support the implementation of electric torque drivers in production environments and ensure they meet functional and performance requirements.
• Evaluate and specify the hardware needed for each torque operation, including drivers, controllers, and related components.
• Create programs for electric torque drivers using ToolsNet software or comparable tightening control platforms.
• Perform validation of implemented torque systems to confirm proper operation, repeatability, and adherence to process specifications.
• Complete clear and accurate documentation for torque systems, including configuration details, validation records, and operating procedures.
• Design, implement, and optimize medium to high complexity control systems aligned with industry standards and project requirements.
• Participate in system commissioning activities and verify that designs meet functional, performance, and safety expectations.
• Develop and maintain controls documentation such as electrical diagrams, functional specifications, user manuals, and validation reports.
• Conduct risk assessments to identify hazards in machinery, automated systems, and industrial processes.
• Design and integrate safety control systems, including safe PLC configurations, emergency stop circuits, interlocks, and protective devices.
• Ensure compliance with relevant safety and regulatory standards, including OSHA, ANSI, RIA, ISO/EN, and other applicable guidelines.
• Perform validation and proof testing of safety functions to ensure proper operation, reliability, and adherence to safety requirements.
• Provide consultation on machine guarding, safety code compliance, and internal safety practices to support safe operations.
• Analyze and resolve moderately complex production and development issues using structured problem-solving tools such as DOE, Six Sigma, and statistical methods.
• Evaluate and integrate emerging technologies into small scale or moderately complex control and automation systems.
• Develop and optimize programs for advanced automation, data handling, and system analytics to improve process performance.
• Implement robust software practices to ensure data integrity, consistency, and cybersecurity within control systems.
• Configure industrial communication networks such as Modbus, PROFINET, and EtherNet/IP, including switches, VLANs, and device-to-system data exchange.
• Use advanced data analysis techniques to identify trends, correlations, and opportunities for process and system improvements.
• Analyze system data to drive measurable improvements in cycle time, throughput, and equipment utilization.
• Leverage new control technologies to improve process reliability, efficiency, and maintainability.
• Lead medium-sized controls projects, including scoping, resource coordination, and implementation of process improvements.
• Present technical concepts, project status, and recommendations to leadership and collaborate effectively across departments.
• Mentor entry-level engineers and interns by providing guidance, feedback, and support in technical troubleshooting, PLC programming, automation, HMI development, and controls engineering best practices.

Essential Skills

• Bachelor's degree is required, with an engineering discipline strongly preferred.
• At least 2 years of experience in controls engineering or a closely related field for the Controls Engineer opening.
• At least 10 years of experience in controls engineering or a closely related field for the Sr. Controls Engineer (Safety-Focused) opening.
• Hands-on experience with electric torque drivers and software used to control tightening processes.
• Proficiency in PLC programming, with experience in major industrial PLC platforms.
• Ability to design, implement, and optimize medium to high complexity control and automation systems.
• Experience conducting risk assessments for machinery, automated systems, and industrial processes.
• Capability to design and integrate safety control systems, including safe PLC configurations, emergency stops, interlocks, and protective devices.
• Familiarity with and ability to apply relevant safety and regulatory standards such as OSHA, ANSI, RIA, ISO/EN in controls and safety designs.
• Strong analytical and problem-solving skills using structured methods including DOE, Six Sigma, and statistical analysis.
• Experience configuring and troubleshooting industrial communication networks such as Modbus, PROFINET, and EtherNet/IP.
• Ability to develop and optimize automation, data handling, and system analytics programs to support production and development operations.
• Strong documentation skills for creating electrical diagrams, functional specifications, user manuals, and validation reports.
• Demonstrated ability to lead controls projects and collaborate with cross-functional teams.

Additional Skills & Qualifications

• Experience with ToolsNet software for programming and managing electric torque drivers is a significant plus.
• Knowledge of PF6000 torque systems and related hardware is highly desirable.
• Exposure to other brands of electric torque drivers and tightening control software is beneficial.
• Proficiency with standards such as ANSI B11 (Safety of Machinery), ANSI/ISA-84, and electrical standards for industrial machinery is advantageous.
• Working knowledge of OSHA 29 CFR 1910 and related safety regulations supports effective compliance and safety engineering.
• Experience implementing robust software practices focused on data integrity, consistency, and cybersecurity in industrial environments.
• Experience in advanced data analysis techniques to identify trends and optimization opportunities in manufacturing systems.
• Experience mentoring junior engineers or interns and providing technical leadership within engineering teams.
• Strong communication skills to present technical concepts and recommendations clearly to both technical and non-technical stakeholders.

Job Type & Location

This is a Contract position based out of Rockford, IL.

Pay and Benefits

The pay range for this position is $50.00 - $60.00/hr.

Eligibility requirements apply to some benefits and may depend on your job classification and length of employment. Benefits are subject to change and may be subject to specific elections, plan, or program terms. If eligible, the benefits available for this temporary role may include the following:

• Medical, dental & vision
• Critical Illness, Accident, and Hospital
• 401(k) Retirement Plan - Pre-tax and Roth post-tax contributions available
• Life Insurance (Voluntary Life & AD&D for the employee and dependents)
• Short and long-term disability
• Health Spending Account (HSA)
• Transportation benefits
• Employee Assistance Program
• Time Off/Leave (PTO, Vacation or Sick Leave)

Workplace Type

This is a fully onsite position in Rockford,IL.

Application Deadline

This position is anticipated to close on Jul 16, 2026.

About Actalent

Actalent is a global leader in engineering and sciences services and talent solutions. We help visionary companies advance their engineering and science initiatives through access to specialized experts who drive scale, innovation and speed to market. With a network of almost 20,000 consultants and 5,000 clients across the U.S., Canada, Asia and Europe, Actalent serves many of the Fortune 500. We are proud to be an Engineering News-Record (ENR) Top 500 Design Firm for our engineering design services and a ClearlyRated Best of Staffing winner for both client and talent service.

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