Controls Engineer / PLC Technician

Position Summary

The Controls Engineer / PLC Technician is responsible for the maintenance, troubleshooting, programming, optimization, and continuous improvement of automation and control systems throughout the manufacturing facility. This role supports approximately 30 injection molding machines, automated assembly lines, robotics, vision systems, material handling equipment, and facility automation systems.

The Controls Engineer serves as the plant's subject matter expert for Allen-Bradley and Siemens PLC platforms and is responsible for minimizing equipment downtime, improving machine performance, supporting new equipment integration, and ensuring reliable operation of all manufacturing control systems.

This position works closely with Maintenance, Production, Quality, Tooling, and Engineering teams to support operational excellence, equipment reliability, and continuous improvement initiatives.

Duties & Responsibilities

• Troubleshoot, diagnose, and repair electrical, controls, automation, and communication system failures.
• Support and maintain Allen-Bradley and Siemens PLC-controlled equipment throughout the facility.
• Develop, modify, back up, and document PLC programs as required.
• Perform root cause analysis of equipment and process failures.
• Implement corrective actions to improve equipment reliability and performance.
• Support machine startups, process troubleshooting, and production optimization.
• Assist maintenance technicians with electrical and controls troubleshooting.
• Support mold and process validation activities.
• Optimize machine cycle times and equipment performance where appropriate.
• Modify and enhance PLC and HMI programs to improve safety, quality, reliability, and productivity.
• Develop and maintain electrical schematics and controls documentation.
• Create and maintain equipment backups for all PLC, HMI, robot, and vision system programs.
• Support new equipment installations, launches, and capital projects.
• Participate in equipment acceptance testing, startup, and commissioning activities.
• Ensure change management procedures are followed for all programming modifications.
• Troubleshoot and maintain industrial communication networks including:
• OTHER REASONABLE DUTIES AS ASSIGNED.

Qualifications & Requirements

• Associate Degree in Electrical Engineering Technology, Mechatronics, Industrial Automation, or related technical field preferred.
• Bachelor's degree in electrical engineering, Controls Engineering, Automation Engineering, or related field preferred for Engineer-level candidates.
• Equivalent technical training and experience may be considered.

PLC Technician

• 3+ years of industrial controls and automation experience.
• Manufacturing experience required.
• Injection molding and automotive experience preferred.

Controls Engineer

• 5+ years of industrial controls engineering experience.
• Automotive manufacturing experience preferred.
• Project management and equipment launch experience preferred.

Required

• Allen-Bradley PLC systems:
• Studio 5000
• RSLogix 5000
• FactoryTalk View
• Siemens PLC systems:
• TIA Portal
• Step 7
• WinCC
• Electrical troubleshooting:
• 24VDC controls
• 120VAC
• 480VAC systems
• Servo systems
• VFDs
• Automation controls
• Industrial sensors
• Electrical schematics
• Industrial communication networks
• Ability to work around manufacturing equipment and machinery.
• Ability to lift up to 40 pounds occasionally.
• Ability to stand, walk, bend, climb ladders, and work in confined spaces as required.
• Ability to support occasional off-shift and weekend production requirements.

Preferred

• Robotics- fanuc or other
• Cognex Vision Systems
• Keyence Vision Systems
• Injection molding machine controls – engel and arburg
• SAP, or similar ERP systems
• CMMS systems (maintain X or similar)