Job Title: Controls Engineer
Reports to: Maintenance Manager
FLSA Status: EXEMPT
Schedule: Monday – Friday (extended hours and weekends as needed)
Primary Duties and Responsibilities:
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Program and maintain robotic automation systems to support production operations.
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Troubleshoot robotic equipment using controller interfaces, including teach pendants, when systems are out of sync.
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Diagnose, test, and repair programmable logic controllers (PLCs) that operate automated equipment.
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Install, maintain, and repair electrical components of machinery and equipment.
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Perform visual inspections and functional testing of machinery, accurately document maintenance activities.
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Monitor equipment for unusual sounds or performance issues and collaborate with supervisors and maintenance team members to diagnose and resolve malfunctions.
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Maintain appropriate levels of maintenance supplies and perishable inventory.
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Install, maintain, and replace sensors and related components.
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Train production employees on proper equipment operation and safe usage practices.
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Support and participate in continuous improvement initiatives.
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Follow all safety procedures and ensure safe operation of machinery and equipment.
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Maintain 5S standards within the robotic cell department.
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Perform other duties as assigned by management.
General Work Requirements:
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Proficient in RSLogix 5000 (Rockwell Automation) for PLC programming, logic development, and troubleshooting.
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Experience with FANUC robot programming and FactoryTalk for HMI modification and integration.
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Hands-on experience in control panel building, machine wiring, and support of new equipment builds and repurposing projects.
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Demonstrated ability to perform robotic troubleshooting, preventive maintenance, and ladder logic programming.
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Strong knowledge of motor controls, variable frequency drives (VFDs), and related systems.
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Ability to read, interpret, and work from PLC logic, electrical diagrams, technical schematics, and blueprints.
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Advanced troubleshooting skills with a strong focus on root cause analysis and problem resolution.
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Working knowledge of welding and metal forming techniques and processes.
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Experience with both destructive and non-destructive testing methods.
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Bachelor’s degree in Mechanical, Electrical, Manufacturing Engineering, or a related field preferred.
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Minimum of five (5) years of relevant experience in industrial automation, robotics, or maintenance.
Physical environment/work conditions:
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Ability to move throughout the facility, including production floors, warehouses, and office areas
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Must be able to stand and walk for extended periods during audits, inspections, and investigations
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Ability to sit for prolonged periods while working on computers, analyzing data, and completing
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Occasionally lift and/or move items up to 25 pounds (e.g., parts, gauges, or inspection equipment)
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Exposure to manufacturing environments including varying temperatures, noise, moving machinery, and potential airborne particles
