Controls Engineer in Syracuse, New York at Feldmeier Equipment Inc

Job Summary

Feldmeier Equipment is seeking a Controls Engineer to join our Manufacturing Engineering team. This position will play a critical role in supporting, troubleshooting, and improving manufacturing equipment across our facilities. The Controls Engineer will be responsible for reverse engineering legacy equipment, including IMCAR systems, while developing and maintaining controls solutions for new and existing automated equipment. This role combines hands-on troubleshooting with engineering design and continuous improvement initiatives to support production, quality, safety, and operational efficiency.

· Reverse engineer existing manufacturing equipment to understand, document, and improve machine functionality.

· Troubleshoot electrical, controls, PLC, HMI, servo, VFD, and automation-related issues on production equipment.

· Design, develop, modify, and maintain PLC and HMI programs.

· Support the installation, startup, commissioning, and validation of new manufacturing equipment.

· Create and maintain electrical schematics, controls documentation, wiring diagrams, and equipment manuals.

· Work with Manufacturing Engineering, Maintenance, Quality, and Production teams to identify and implement process improvements.

· Analyze machine performance data and recommend improvements to increase equipment reliability and efficiency.

· Develop preventive maintenance recommendations and troubleshooting procedures.

· Assist with integrating robotics, automation technologies, and Industry 4.0 initiatives where applicable.

· Support vendors, contractors, and equipment manufacturers during installations, upgrades, and repairs.

· Train maintenance technicians and production personnel on equipment operation and troubleshooting.

· Ensure all equipment controls comply with safety standards and company policies.

· Participate in root cause analysis and corrective action activities for equipment failures and production issues.

· Bachelor's degree in Electrical Engineering, Controls Engineering, Mechatronics Engineering, or related field; equivalent experience may be considered.

· Minimum 3 years of experience in industrial controls engineering, automation, or manufacturing engineering.

· Experience programming and troubleshooting PLC systems; Allen-Bradley experience preferred.

· Experience with HMI development and industrial networking.

· Strong understanding of electrical systems, sensors, motors, drives, and control circuits.

· Ability to read and create electrical schematics and technical documentation.

· Strong problem-solving and analytical skills.

· Ability to work independently and manage multiple projects simultaneously.

· Experience reverse engineering machinery and legacy control systems.

· Experience with servo systems, motion control, and automated manufacturing equipment.

· Familiarity with robotics and automated welding systems.

· Experience using AutoCAD Electrical or similar electrical design software.

· Understanding of manufacturing processes involving stainless steel fabrication, welding, machining, rolling, or forming equipment.

· Knowledge of industrial communication protocols including Ethernet/IP, Modbus, and Profinet.

· Ability to work in both office and manufacturing environments.

· Ability to stand, walk, climb ladders, and access manufacturing equipment.

· Ability to occasionally lift up to 50 pounds.

· Ability to work around energized electrical and automated equipment while following all safety procedures.

· Reduced equipment downtime.

· Improved machine reliability and production efficiency.

· Successful implementation of automation and controls improvements.

· Complete and accurate controls documentation.

· Effective support of production and maintenance teams.