Senior Machine Controls Engineer
Twinsburg, OH
$120-130,000
We are seeking an experienced Senior Machine Controls Engineer / PLC Programmer for our facility in Twinsburg to design, program, integrate, and support state-of-the-art vinyl window welding, sawing, corner cleaning, fabrication, and conveyance systems.
This position is ideal for a hands-on controls professional who enjoys taking automated machinery from concept through design, programming, startup, commissioning, and customer support. Qualified candidates should possess strong experience with PLC programming, machine control design, HMI development, motors, drives, electro-mechanical devices, wiring schematics, and industrial automation.
Responsibilities
- Interface with customers, sales, project management, mechanical engineering, manufacturing, and field service teams to define project requirements.
- Work with the Sales team to develop project estimates, technical concepts, and automation solutions.
- Design electrical controls for automated vinyl window manufacturing equipment, including welding, sawing, corner cleaning, fabrication, material handling, and conveyance systems.
- Develop, modify, test, and troubleshoot PLC software for machine control and automation systems.
- Develop and improve HMI screens for operator control, machine diagnostics, alarms, production data, and ease of use.
- Create complete electrical schematics, panel layouts, I/O lists, wiring diagrams, bills of materials, and supporting documentation.
- Program and integrate servo drives, VFDs, motors, sensors, safety devices, vision systems, pneumatic and hydraulic devices, and industrial communication networks.
- Support machine debug, factory acceptance testing, installation, startup, commissioning, and site acceptance testing at customer facilities.
- Provide technical support for customers, manufacturing, sales, and field service teams.
- Troubleshoot PLC logic, HMI applications, electrical systems, motion control, machine networks, field devices, and control panels.
- Drive productivity, safety, reliability, and operator-experience improvements through updates to programming, equipment, diagnostics, and HMI screens.
- Develop, update, modify, and continuously improve existing controls systems, including robotic programs, PLC programs, relay logic, electrical distribution, motor controls, operator interfaces, hydraulics, and pneumatics.
- Prepare and maintain clear technical documentation, including machine manuals, service notes, software backups, and change records.
- Support standardization of controls architecture, software structure, programming libraries, and machine documentation.
- Travel to customer sites as required for installation, commissioning, troubleshooting, service support, and training.
Qualifications
- Bachelor of Science degree in Electrical Engineering, Automation Engineering, Mechatronics, or equivalent practical experience.
- 5+ years of electrical controls experience in machine design, industrial automation, systems integration, or a similar role.
- Strong PLC programming experience, including machine sequencing, diagnostics, safety logic, motion control, and troubleshooting.
- Experience with HMI programming and operator-interface design.
- Experience with servo motion, VFDs, motors, sensors, safety circuits, industrial networks, and automated machinery.
- Experience with structured programming methods such as Ladder Logic, Function Block, Structured Text, and object-oriented PLC programming.
- Experience with Beckhoff TwinCAT 3. Experience with Jetter / Bucher control systems preferred.
- Experience with robotics, vision systems, machine safety, and automated production systems is a plus.
- Working knowledge of Microsoft Office products.
- Ability to read and develop electrical schematics, panel layouts, I/O drawings, and machine documentation.
- Strong troubleshooting, analytical, and problem-solving skills.
- Strong communication skills, both verbal and written.
- Positive attitude, detail-oriented work style, high sense of ownership, and strong customer-service mindset.
- Must be dependable, reliable, self-motivated, and driven to succeed.
- Willingness to travel domestically and internationally as required.
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