Controls Engineer

Job Title: Controls Engineer

Location: Onsite | Troy, Ohio

Salary: $100,000 - $115,000 annually

Employment Type: Full-Time

Reports To: Engineering and Maintenance Manager

IF INTERESTED - CALL/TEXT MIKE HANSON WITH GENTIS SOLUTIONS

(612) 910-5197

mhanson@gentissolutions.com

Requirements

• 8+ years of controls engineering, industrial automation, or equipment integration experience in manufacturing
• Extensive hands-on PLC programming, modification, and troubleshooting experience
• Experience integrating, installing, commissioning, and supporting automated manufacturing equipment
• Strong knowledge of HMIs, VFDs, servo systems, industrial sensors, safety circuits, and industrial networks
• Experience with electrical troubleshooting, schematics, control-panel layouts, and controls design
• Bachelor’s degree in Controls Engineering, Electrical Engineering, Automation Engineering, or a related technical field

Plusses

• Siemens PLC and automation experience
• Strong Allen-Bradley or comparable PLC experience
• Industrial robotics programming and integration experience
• Conveyor or automated material-handling equipment experience
• Lamination, coating, web-handling, or roll-to-roll manufacturing experience
• Electrical control-panel design and controls hardware selection experience

___________________________________________________________________________________

Role Overview: Hands-on controls engineering role focused on designing, integrating, troubleshooting, and improving industrial control systems and automated manufacturing equipment. This person will support production and maintenance by resolving complex controls issues, improving equipment reliability, and implementing automation upgrades

Team Environment: Works closely with engineering, maintenance, production, quality, equipment manufacturers, and systems integrators. The Controls Engineer will also provide technical leadership, training, and troubleshooting support to employees working with automated equipment

Core Responsibilities

• Design, program, modify, and troubleshoot PLC-based control systems
• Develop and modify HMI applications, control logic, alarms, recipes, and operator interfaces
• Troubleshoot PLCs, HMIs, drives, sensors, safety systems, and industrial communication networks
• Lead equipment integration, installation, startup, and commissioning activities
• Support robotics, conveyor systems, automated material handling, lamination equipment, and related manufacturing technologies
• Diagnose complex electrical, controls, and automation issues affecting production
• Perform root cause analysis and implement corrective actions for recurring controls failures
• Create and update electrical schematics, control-panel layouts, wiring diagrams, and equipment documentation
• Specify electrical components and controls hardware for new equipment and modifications
• Maintain PLC, HMI, electrical drawing, and controls configuration documentation
• Identify automation improvements that increase uptime, productivity, quality, and safety
• Upgrade obsolete controls components and support system modernization
• Participate in capital projects, equipment upgrades, and production launches
• Train maintenance technicians, operators, and other employees on controls systems and troubleshooting

Requirements

• Strong PLC programming, modification, and troubleshooting experience
• Manufacturing automation and equipment integration experience
• Knowledge of HMIs, VFDs, servo systems, industrial sensors, safety circuits, and industrial networks
• Electrical troubleshooting and controls design experience
• Strong analytical, troubleshooting, project-management, and problem-solving skills
• Ability to work effectively with production, maintenance, engineering, vendors, and systems integrators
• Strong technical documentation, communication, and employee-training skills

Ideal Candidate Background: Experienced manufacturing controls engineer with deep hands-on PLC and equipment integration experience. The strongest candidate will be comfortable troubleshooting complex production issues, commissioning automated equipment, improving existing control systems, and working directly with maintenance and production teams. Siemens experience is preferred, but strong Allen-Bradley or comparable PLC experience will also be considered

Typical Day: Troubleshoot production equipment, modify PLC and HMI programming, support maintenance and production teams, investigate recurring equipment failures, assist with equipment installations and startups, update electrical and controls documentation, and work on automation improvements and modernization projects

Task Breakdown and Workflow: PLC programming and troubleshooting | HMI development | Equipment integration and commissioning | Production support | Root cause analysis | Electrical troubleshooting | Controls documentation | Automation upgrades | Equipment modernization | Capital project support | Employee training | Vendor and integrator coordination

You should be proficient in:

• PLC Troubleshooting Skills
• Electrical Troubleshooting Skills
• Electrical Systems Diagnostics & Repair
• Electrical Troubleshooting
• PLC Programming Experience
• PLC Wiring Experience
• Electrical / Electronic Systems
• Electrical Systems & Diagnostics (Heavy Equipment)
• Electrical Panel Installation
• Electrical Schematic Reading

Machines & technologies you'll use:

• Industrial Controls (Siemens, Allen Bradley)
• Variable Frequency Drives (VFD)
• Programmable Logic Controller (PLC) (Siemens, Allen Bradley)
• HMI
• Servo Motors