The Controls Leader serves as the site's strategic subject matter expert for electrical power distribution, process controls, automation, and instrumentation systems. This role provides technical leadership for large-scale capital projects, long-term control system strategy, equipment modernization initiatives, and overall plant reliability improvements.
Unlike a hands-on controls engineering role focused on smaller projects and daily troubleshooting, the Controls Leader operates from a broader systems perspective, providing direction and oversight for major Electrical & Instrumentation (E&I) initiatives, power and controls master planning, standards development, and technician capability building.
The successful candidate will collaborate with Engineering, Operations, Maintenance, Quality, and Safety teams to ensure reliable, compliant, and efficient control systems that support plant performance and future growth.
Ideal Candidate Profile
This position is ideal for a senior controls professional who enjoys leading plant-wide automation strategy, capital projects, and technical development efforts while remaining connected to manufacturing operations. The successful candidate will bring deep Allen-Bradley/Rockwell expertise, experience in food, pharmaceutical, or similarly regulated manufacturing environments, and the ability to think at a plant-wide, strategic level rather than focusing solely on day-to-day controls support.
Key ResponsibilitiesControls & Power Systems Leadership
- Serve as a primary technical leader and escalation resource for plant power distribution, controls, automation, and instrumentation systems.
- Develop and maintain site standards for electrical and control systems and ensure consistent application across all capital projects and facility upgrades.
- Lead execution of the plant's long-term power and controls master plan, including lifecycle management and replacement strategies for obsolete equipment and technologies.
- Drive system reliability, performance optimization, and continuous improvement initiatives.
Capital Projects & Engineering Support
- Provide controls and power engineering leadership on large-scale capital projects and facility expansion initiatives.
- Partner with the Engineering Projects Manager to define project scope, standards, and technical requirements.
- Support equipment selection, installation, commissioning, startup, and performance validation.
- Review and influence equipment designs to ensure maintainability, reliability, and compliance with site standards.
- Act as the site expert for new control systems and automation technologies.
Automation & Data Systems
- Support the design and implementation of automation solutions, including PLC programming strategies, HMI development, MES integration, historian systems, and KPI reporting.
- Validate and maintain PLC-generated data utilized by MES and manufacturing analytics systems.
- Collaborate with Process Engineers to develop control strategies and improve data availability for process optimization.
- Lead evaluation and implementation of emerging automation technologies.
E&I Leadership & Workforce Development
- Establish and maintain a structured development program for E&I technicians.
- Assess technician skill levels and create training and development plans.
- Provide coaching, mentoring, and technical leadership to E&I personnel.
- Set daily priorities and direction for technical resources while fostering a culture of safety, accountability, and continuous learning.
- Although this role does not have direct reports, it provides technical leadership and functional guidance to E&I technicians and project teams.
Safety, Compliance & Quality Systems
- Ensure compliance with applicable regulatory standards, including NFPA 70, NFPA 70E, NFPA 79, and OSHA 1910.
- Lead initiatives related to electrical safety programs, including LOTO, energized work permitting, arc flash protection, PPE requirements, and electrical qualifications.
- Support quality and food safety systems involving critical control points, checkweighers, metal detectors, vision systems, ingredient flow controls, and temperature monitoring.
- Ensure control systems comply with company, regulatory, and customer requirements.
Operational Excellence
- Partner with Operations, Engineering, and Maintenance teams to identify and eliminate losses related to safety, quality, uptime, reliability, and cost.
- Support troubleshooting of complex power, controls, and automation issues as needed.
- Utilize control system data, simulation tools, and process modeling techniques to improve plant performance and asset reliability.
QualificationsEducation
- Bachelor's degree in Engineering required
- Electrical Engineering degree strongly preferred.
Experience
- Minimum of 5 years of controls engineering experience in a manufacturing environment.
- Food, pharmaceutical, or other highly regulated manufacturing experience strongly preferred.
- Experience leading controls engineering efforts for large-scale capital projects and plant-wide automation initiatives.
- Experience supporting electrical infrastructure, process control systems, and industrial automation environments.
- Demonstrated success implementing equipment installations and startup activities in manufacturing facilities.
Technical Skills
- Must have strong expertise with Allen-Bradley PLC platforms and Rockwell Automation technologies.
- Experience with FactoryTalk applications and related automation software.
- Knowledge of process instrumentation, industrial networking, power distribution systems, and control system architecture.
- Experience with MES systems, manufacturing historians, and industrial data integration.
- Working knowledge of NFPA and OSHA electrical safety standards.
- Proficiency with Microsoft Office applications.
Leadership Competencies
- Ability to influence and lead cross-functional teams without direct supervisory authority.
- Strong coaching, mentoring, and technician development skills.
- Excellent communication, presentation, and interpersonal abilities.
- Strong analytical, organizational, and problem-solving capabilities.
- Self-motivated with demonstrated success driving technical initiatives and continuous improvement programs.
Working Conditions
- Primarily based within a manufacturing facility of approximately 500 employees.
- Significant time spent on the production floor supporting operations and project activities.
- Occasional physical work involving manufacturing equipment.
- Ability to respond to off-shift and weekend support needs as required.
- Limited travel may be required.
Compensation & Benefits
- Competitive base salary
- 10% annual bonus opportunity
- Comprehensive benefits package
- Career growth and leadership development opportunities
Ideal Candidate Profile
This position is ideal for a senior controls professional who enjoys leading plant-wide automation strategy, capital projects, and technical development efforts while remaining connected to manufacturing operations. The successful candidate will bring deep Allen-Bradley/Rockwell expertise, experience in food, pharmaceutical, or similarly regulated manufacturing environments, and the ability to think at a plant-wide, strategic level rather than focusing solely on day-to-day controls support.
Pay: $110,000.00 - $129,000.00 per year
Work Location: In person
