Principal Controls Engineer

Scope and Decision Rights

· Lead assigned technical reviews and make release-readiness recommendations within delegated authority.

· Establish and maintain recommended architecture, programming, HMI, network, cybersecurity, testing, and documentation practices approved by the Manager.

· Identify and escalate technical, safety, quality, cybersecurity, schedule, or lifecycle risks.

· Stop or delay assigned technical work when released requirements, review evidence, test readiness, or safety controls are inadequate.

· Mentor and provide technical direction without assuming people-management authority unless formally assigned.

Essential Duties and Responsibilities

· Define standard automation architectures for hot cells, Glycol Systems, Deicing Solutions, and related product platforms.

· Establish PLC programming standards, reusable libraries, state models, sequencing methods, alarm strategies, diagnostics, tag structures, and software-documentation requirements.

· Establish HMI standards for navigation, visualization, alarms, operator guidance, security, trends, recipes, maintenance, and user experience.

· Define industrial network architecture, device integration, remote I/O, communications, data exchange, cybersecurity, backup, restore, and remote-access practices.

· Translate functional requirements and FDS content into complete controls design packages, software designs, I/O definitions, interface documents, test plans, and controlled releases.

· Lead software, electrical, controls, and integrated design reviews and confirm systems are testable, maintainable, serviceable, secure, and supportable.

· Develop simulation, emulation, code-review, automated-test, and version-control practices that improve quality before FAT.

· Lead difficult troubleshooting, commissioning, and root-cause investigations and convert lessons into controlled platform improvements.

· Mentor engineers and technicians through reviews, pairing, coaching, standards development, and practical instruction.

· Evaluate technology and recommend adoption based on business value, lifecycle support, cybersecurity, availability, standardization, and cost.

Working Interfaces

· Director, Automation & Electrical Systems: strategy, priorities, budget, staffing, department performance, capacity, major technical risk, and escalation.

· Product Management: product requirements, roadmap priorities, standard-versus-custom decisions, cost targets, and product performance.

· Product Design & Engineering: equipment functions, physical interfaces, sensor and actuator requirements, safety devices, pneumatics, serviceability, and integrated design reviews.

· Panel Shop: released schematics, panel layouts, BOMs, component requirements, UL considerations, technical clarifications, redlines, and controlled changes.

· Electrical Integration: released wiring packages, cable schedules, I/O definitions, device requirements, checkout support, energization readiness, and as-built feedback.

· Project Management: estimates, assumptions, schedules, technical status, risks, changes, customer technical communication, and recovery actions.

· cGMP & Acceptance Testing: FDS content, traceability, FAT/SAT support, approved software versions, deviations, test evidence, and turnover records.

Required Skills and Abilities

· Expert PLC programming, HMI, controls architecture, electrical design, industrial networking, system integration, and machine/process sequencing knowledge.

· Advanced Rockwell Automation, Studio 5000, FactoryTalk View, or equivalent platform proficiency.

· Strong instrumentation, I/O, drives, motors, valves, pneumatics, safety circuits, interlocks, alarms, recipes, and data-system knowledge.

· Demonstrated ability to create reusable software, standard architectures, test methods, and maintainable design practices.

· Strong Working knowledge of AutoCAD Electrical.

· Ability to interpret schematics, panel layouts, P&IDs, sequence documents, mechanical designs, and customer requirements.

· Strong mentoring, technical writing, troubleshooting, communication, and customer-facing capability.

Education and Experience

· Bachelor’s degree in Electrical Engineering, Controls Engineering, Automation Engineering, Computer Engineering, or related field; equivalent relevant experience may be considered.

· Typically 10 or more years of progressive controls and automation experience with recent hands-on responsibility for complex industrial systems.

· Demonstrated experience developing, commissioning, documenting, and improving reusable automation platforms through multiple product or project cycles.

· Experience with regulated, validated, pharmaceutical, radiopharmaceutical, or similarly controlled equipment is preferred.

Success Measures

· Automation platforms are reusable, maintainable, documented, testable, secure, and scalable.

· FAT readiness improves through simulation, disciplined reviews, and standardized testing.

· Software defects, commissioning time, field issues, and configuration errors decrease.

· Engineers and technicians show measurable growth in architecture, programming, troubleshooting, documentation, and design ownership.

· Lessons become controlled standards, libraries, and retained organizational knowledge.

Physical and Work Requirements

· Prolonged computer, programming, and technical-review work.

· Regular presence in Panel Shop, equipment assembly, testing, and production areas.

· Travel to customer sites for commissioning and critical issue resolution.

· Compliance with PPE, electrical safety, lockout/tagout, cybersecurity, and site requirements