Industrial Controls Technician

The successful candidate will have extensive experience diagnosing and resolving controls-related problems in a manufacturing environment, with particular emphasis on PLC troubleshooting, Cognex vision systems, HMI interfaces, and industrial automation. This position is ideal for a technically strong, hands-on controls professional who enjoys troubleshooting complex automated manufacturing equipment and resolving PLC, HMI, and industrial control system issues.

Job Description: Industrial Controls Technician Location: Buffalo Grove, IL Employment Type: Direct Hire Shift:1st Compensation:40-45/hr. Position Overview Sterling Engineering is seeking an experienced Industrial Controls Technician to support a highly automated manufacturing operation in Buffalo Grove, IL. This position is ideal for a technically strong, hands-on controls professional who enjoys troubleshooting complex automated manufacturing equipment and resolving PLC, HMI, and industrial control system issues. While titled Industrial Controls Technician, this role requires a level of technical expertise comparable to a junior Controls Engineer. The successful candidate will have extensive experience diagnosing and resolving controls-related problems in a manufacturing environment, with particular emphasis on PLC troubleshooting, Cognex vision systems, HMI interfaces, and industrial automation. Key Responsibilities - Perform advanced troubleshooting, diagnostics, and repair of PLC-controlled automated manufacturing equipment to minimize production downtime. - Troubleshoot PLC logic, I/O, communication faults, and control system issues to identify and resolve equipment failures. - Diagnose and troubleshoot HMI systems, operator interfaces, RFID systems, and related industrial communication devices. - Troubleshoot, maintain, and support Cognex vision inspection systems, including cameras, sensors, and associated software. - Perform troubleshooting and maintenance of servo motors, servo drives, variable frequency drives (VFDs), and motion control systems. - Support PLC and HMI software modifications, upgrades, and functional verification activities. - Diagnose industrial networking and communication issues between PLCs, HMIs, sensors, drives, and automated equipment. - Read and interpret electrical schematics, wiring diagrams, PLC programs, and technical documentation. - Partner with engineering, maintenance, and production teams to identify root causes of recurring equipment failures and implement corrective actions. - Provide hands-on technical support for complex automated production lines during night shift operations. - Assist with equipment upgrades, automation improvements, and qualification activities. - Document troubleshooting activities, repairs, and system modifications in accordance with manufacturing and quality requirements. - Provide technical guidance and support to maintenance and automation technicians when resolving complex controls issues. - Maintain compliance with established safety procedures, including electrical safety and equipment troubleshooting protocols. Required Qualifications - **Strong hands-on experience troubleshooting PLC-controlled equipment in an industrial manufacturing environment. - Approximately 6+ years of industrial controls, automation, or related technical troubleshooting experience preferred. - Demonstrated ability to diagnose PLC faults, troubleshoot ladder logic, and resolve controls-related production issues. - Experience troubleshooting HMI systems, operator interfaces, and industrial communication devices. - Experience working with Cognex vision systems or similar industrial machine vision technologies. - Working knowledge of servo drives, VFDs, motion control, sensors, and industrial automation equipment. - Ability to interpret electrical schematics, wiring diagrams, and PLC logic. - Experience supporting high-volume or highly automated manufacturing operations. - Strong analytical troubleshooting skills and the ability to work independently during off-shift production. - Associate degree, military technical training, or vocational training in Industrial Controls, Automation, Electrical Technology, or a related discipline preferred. Preferred Qualifications - Experience with Allen-Bradley/Rockwell PLC platforms, including RSLogix, Studio 5000/Logix Designer, and FactoryTalk. - Experience with Siemens S7 PLC systems. - Experience with Cognex In-Sight vision systems and associated software. - Familiarity with Ignition or similar industrial HMI/SCADA platforms. - Experience troubleshooting RFID devices, industrial networks, and automated inspection equipment. - Background in medical device manufacturing, regulated manufacturing, or other high-volume automated production environments. - Experience performing PLC/HMI software modifications and supporting automation upgrades. - Experience supporting equipment qualification, root cause analysis, and continuous improvement initiatives. Compensation & Benefits - Competitive hourly compensation up to the low $50s/hr, depending on experience. - Additional night shift differential. - Direct-hire employment. - Medical, dental, and vision insurance. - 401(k) with company matching. - Paid vacation and sick time. - Life insurance and short-term/long-term disability coverage. - Tuition reimbursement.