Controls Engineer

Summary of Position
The Control Engineer is responsible for designing, developing, and maintaining electrical control systems for 
industrial machinery and equipment. You will be responsible for working with OEM’s, creating electrical 
drawings, programming PLCs, configuring HMIs, and implementing safety systems to ensure the efficient and 
safe operation of manufacturing processes.

Essential Duties and Responsibilities

• Create electrical drawings for systems, includes control and power circuits, and panel layout.
• Prepare and maintain electrical drawings in AutoCAD Electrical.
• Design and program safety systems (Safety PLC and Controllers).
• Design and develop PLC programming (AB, Omron, Siemens, Beckhoff, etc.).
• Design of industrial networks (Ethernet/IP, EtherCAT, Profinet, DeviceNet, Profibus, RS-232).
• Program and implement HMI (AB, Siemens, Omron, Proface, Automation Direct, etc.).
• Servo motion systems configuring and programming (AB, Omron, Siemens, ClearPath, etc.).
• Machine vision design (Cognex, Keyence, Banner, Omron).
• Assist with machine start-ups (I/O checks, devices setup, program upload, safety system checks, and machine test and debugging).
• Provide instructions and technical scope of work for other controls personnel, electrical panel builders and machine assemblers.
• Initiate preliminary PHSR’s with Safety Engineers as required.
• Complete system documentation including drawing updates, operation manuals, and electronic settings.
• Design and develop new machine controls including electrical, electronic, hydraulic, pneumatic and vision systems.
• Analyze project requirements and perform basic controls troubleshooting to support equipment operations.
• Interface with production, quality, safety and engineering on changes and improvement ideas.
• Support electrical installation by interacting with installers.
• Work with others to detect problems and implement solutions.
• Assist in defining controls architecture, platform, and functionality.
• Identify controller hardware to meet I/O and computational requirements.
• Utilizes PLC/HMI skills and knowledge to resolve problems, contribute to development of new products/processes and maintenance/improvement of existing equipment/processes.
• Completes the actual PLC programming and HMI screen programming for production projects.
• Collects and analyzes data, justify procedural changes or process modifications, and established operating procedures for the plant throughout the life of continuous improvement projects.
• Improve the safety of manufacturing equipment by implementing a controls reliable system in place.
• Contributes to project teams to ensure the successful completion of team objectives.
• Identify procedural changes to improve manufacturing efficiencies.
• Assist management team in the execution and completion of CIP Projects.
• Update, modify, and continuously improve existing controls systems including ladder logic programs, relay logic, electrical distribution, motor controls, operator interface, hydraulics, and pneumatics distribution and control.
• Create, maintain, and keep current all hard copies and electronic data bases: all electrical, hydraulic, and pneumatic schematics; panel layouts; PLC, operator display, operator interface, and robot programs; machine power distribution and all related vendor controls component part documentation.
• Implement and maintain data collection system from shop floor processing equipment.
• Maintain and update controls portion of machine standards.
• Understanding of servo, stepper, or VFD motor control techniques and implementation.
• Designs systems that are compliant with all current environmental and safety regulations, including OSHA, OHSA NEC, NFPA, CSA and Arc Flash

Skills  

• Experience working with and troubleshooting robotics / controls systems, Control Logix PLCs and plant application controls and automation.
• Solid understanding of safety systems design.
• Good oral and written communication skills. Must exhibit professional and courteous communication interaction under pressure.
• Strong technical aptitude working with industrial electrical systems regulations, design and  maintenance, particularly automation and control systems.
• Strong organizational skills and a high level of self-motivation.
• Demonstrated technical project management experience.
• Strong logical and methodical reasoning capabilities.
• Familiarity with Variable Frequency Drives and HMIs.
• Ability to effectively manage multiple issues in a fast-paced work environment.
• Strong analytical and problem-solving skills with the ability to resolve complex issues.
• Strong interpersonal and communication skills (both written and oral).
• Skilled in Microsoft Office applications and AutoCAD software.
• Demonstrated experience in the application of various part sensing technologies, machine vision systems, PLC’s and motion control systems.
• Able to effectively work with external machine builders and system integrators for detail design, build and integration of later stages of machine system implementation.

Traits

• Demonstrated ability to work effectively with cross-functional team members.
• Mechanical aptitude/interest.
• Excellent inter-personal and communication skills both written and verbal.
• Team oriented.
• Commitment to continuous learning.
• High degree of attention to detail, precision and follow through.
• Willing and able to work rotating shifts.
• Be able to conceive and manage small projects.

Education and/or Experience

• University or College degree/diploma in Mechatronics, Electromechanical, Computer Science, Electrical, Engineering, System Design, Controls Technology or equivalent work experience.
• Minimum 5 years in system controls development, design and integration of factory automated equipment.
• Proficiency with AutoCAD and electrical ladder diagrams.
• Strong Control/PLC skills with demonstrated experience in the successful implementation of automation, robotics, and control system integration technologies in manufacturing processes preferred.
• Familiarity with design standards in Canada and US (i.e. CSA, NEC, etc.) preferred.

Physical Requirements

• Must be able to lift and move materials up to 25 pounds independently and participate in team lifts of approximately 60 pounds as required for essential production tasks.
• Must be able to remain in a stationary position or move throughout the production floor for extended periods (for the duration of the shift up to 8+ hours per shift).
• Must be able to operate, position, adjust, or move equipment, tools, or materials necessary for production processes.
• Capable of performing consistent, manual production tasks over long shifts.
• Must be able to work in typical manufacturing environmental conditions, including areas requiring PPE, exposure to noise, and temperature variation.
• Reasonable accommodation may be made to enable individuals with disabilities to perform the essential functions.

Compensation and Benefits

• $90,000 - $105,00 annually
• Paid Time Off (vacation, sick, and holiday) 
• 401(k) Retirement Plan
• Medical/Dental/Vision Insurance Plans
• Health Savings Account option
• Supplemental/Voluntary Insurance Plans
• Employee Assistance Program
• Tuition Reimbursement Program 
• Employee Recognition Programs
• Employee PV Panel Purchase Program