Manufacturing Controls Engineer

$114,400 - $135,200/Yr

Russell Tobin - Louisville, KY

Full-time - Mid Level

Louisville, KY

Administrative and Support Services

About the position

The Manufacturing Controls Engineer will develop, implement, and support electrical and automation systems across North American Manufacturing facilities. This role focuses on ensuring the efficient and safe operation of manufacturing processes through expertise in control systems, PLC programming, HMI design, and troubleshooting automation equipment. The engineer will collaborate with cross-functional teams to drive continuous improvement and maintain compliance with industry standards.

Responsibilities

• Design, program, and troubleshoot PLC, HMI, and SCADA systems for manufacturing processes.
• Develop control strategies to optimize the performance of production equipment.
• Create electrical schematics and control panel layouts.
• Oversee the installation and commissioning of automated systems, ensuring proper setup and functionality.
• Program and configure variable frequency drives, servo motors, and other automated equipment.
• Conduct Factory Acceptance Tests and Site Acceptance Tests to ensure systems meet performance and safety standards.
• Provide technical support for electrical and control systems, diagnosing and resolving issues in a timely manner.
• Monitor system performance and make adjustments as needed to improve efficiency and reliability.
• Develop and maintain documentation, including control system schematics, software, and operational manuals.
• Identify opportunities for improving manufacturing efficiency and quality through automation and control system upgrades.
• Lead and participate in root cause analysis for equipment failures and process inefficiencies.
• Implement best practices for predictive maintenance, automation standards, and safety protocols.
• Ensure all control systems comply with industry standards, such as OSHA, NEC, and IEC.
• Develop and enforce safety protocols related to electrical and control systems.
• Stay updated on relevant industry technologies, regulations, and trends.
• Work closely with mechanical, electrical, and process engineers to ensure seamless integration of control systems with other systems.
• Collaborate with production, maintenance, and quality teams to support continuous improvement of manufacturing processes.

Requirements

• Bachelor's degree in Electrical Engineering, Automation, Control Systems Engineering, or a related field.
• 3+ years of experience in controls engineering within a manufacturing environment.
• Proficiency in PLC programming (e.g., Allen-Bradley, Siemens, Schneider Electric).
• Experience with HMI/SCADA development (e.g., Wonderware, Ignition).
• Knowledge of electrical design tools (e.g., AutoCAD Electrical, EPLAN).
• Strong understanding of industrial networking (Ethernet/IP, Modbus, Profibus).
• Familiarity with machine safety standards (e.g., OSHA, ISO 13849).
• Ability to read and interpret electrical schematics and P&ID diagrams.
• Strong analytical, problem-solving, and communication skills.

Nice-to-haves

• Experience with robotics, vision systems, and advanced automation technologies.
• Knowledge of Lean Manufacturing, Six Sigma, or other continuous improvement methodologies.
• Experience with data acquisition systems and IoT technologies in manufacturing.

Benefits

• Comprehensive healthcare coverage (medical, dental, and vision plans)
• Supplemental coverage (accident insurance, critical illness insurance, and hospital indemnity)
• 401(k) retirement savings
• Life & disability insurance
• Employee assistance program
• Identity theft protection
• Legal support
• Auto and home insurance
• Pet insurance
• Employee discounts with some preferred vendors