Summary

The Controls Engineer is responsible for designing, implementing, and maintaining control systems across multiple production facilities to ensure optimal performance, reliability, and efficiency of manufacturing processes. This role provides technical expertise in automation, PLCs, robotics, and other control systems, while supporting continuous improvement initiatives and troubleshooting complex issues. You need a strong background in controls engineering, project management, and cross-functional collaboration within a food manufacturing or similar environment to be successful.

Duties and Responsibilities

Essential Functions

Control System Design and Implementation:

• Design, program, and troubleshoot PLC (Programmable Logic Controller) systems, HMI (Human-Machine Interface) panels, and SCADA (Supervisory Control and Data Acquisition) systems.
• Develop and implement control system solutions to improve production efficiency, product quality, and equipment reliability.
• Lead the integration of new equipment and automation technologies into existing production lines.
• Create and maintain electrical schematics, control system documentation, and standard operating procedures (SOPs).

Technical Support and Troubleshooting:

• Provide on-site and remote support to multiple production facilities to resolve control system issues and minimize downtime.
• Diagnose and troubleshoot complex electrical, mechanical, and software-related problems in control systems.
• Collaborate with maintenance, production, and engineering teams to identify root causes of equipment failures and implement corrective actions.
• Conduct regular system audits to ensure control systems are operating efficiently and in compliance with safety and regulatory standards.

Project Management:

• Manage controls-related projects, including scope definition, budgeting, scheduling, and resource allocation.
• Coordinate with external vendors, contractors, and internal stakeholders to ensure timely and successful project completion.
• Oversee the installation, commissioning, and validation of new control systems and equipment upgrades.
• Ensure all projects adhere to food safety regulations (e.g., FDA, USDA, HACCP) and electrical standards (e.g., NFPA 70, NEC).

Continuous Improvement:

• Identify opportunities to optimize control systems and processes through data analysis, automation, and advanced technologies.
• Implement lean manufacturing principles and Six Sigma methodologies to drive operational excellence.
• Stay updated on industry trends, emerging technologies, and best practices in controls engineering and automation.

Training And Development:

• Train maintenance and production staff on the operation, troubleshooting, and maintenance of control systems.
• Develop training materials and conduct hands-on workshops to enhance technical skills across facilities.
• Compliance And Safety
• Ensure all control systems comply with food safety regulations (e.g., GMP, HACCP) and electrical safety standards (e.g., OSHA, NFPA 70E).
• Conduct risk assessments and implement safety measures to protect personnel and equipment.
• Maintain accurate records of control system modifications, repairs, and compliance documentation.

Supervisory Responsibilities

None

Machines, Equipment, Tools Used

Personal computer, standard office equipment, own or company vehicle.

Physical Demands

Reaching: Extending hand(s) and arm(s) in any direction.

Walking: Moving about on foot to accomplish tasks, particularly for long distances or moving from one work site to another.

Fingering: Picking, pinching, typing or otherwise working, primarily with the fingers rather than with the whole hand or arm as in handling.

Grasping: Applying pressure to an object with the fingers and palm.

Talking: Expressing or exchanging ideas by means of the spoken word. Those activities in which they must convey detailed or important spoken instructions to other workers accurately, loudly, or quickly.

Hearing: Perceiving the nature of sounds at normal speaking levels with or without correction. Ability to receive detailed information through oral communication, and to make find discriminations in sound.

Light Work: Exerting up to 20 pounds of force occasionally, and/or up to 10 pounds of force frequently, and/or a negligible amount of force constantly to move objects. If the use of arm and/or leg controls requires exertion of forces greater than that for Sedentary Work and the worker sits most of the time, the job is rated for light work.

The employee is required to have close visual acuity to perform an activity such as: preparing and analyzing data and figures: transcribing; viewing a computer terminal; extensive reading; visual inspection involving small defects, small parts, and/or operation of machines (including inspection); using measurement devices; and/or assembly or fabrication of parts at distances close to the eyes.

Work Environment

Office, plant, and shop conditions as well as occasional but often lengthy exposure to outside conditions.. Long work days and workweeks required. Access to certain confidential data.

Disclaimer: The above statements are intended to describe the general nature and level of work being performed by individuals assigned to this job. They are not intended to be an exhaustive list of all responsibilities, duties and skills required of the position. All employees may have other duties assigned at any time.

Knowledge, Skills and Abilities

• Bachelor’s degree in Electrical Engineering, Controls Engineering, Automation, or a related field or equivalent experience
• 3+ years of experience in controls engineering, preferably in food manufacturing or a similar industry.
• Proficiency in programming and troubleshooting PLCs (e.g., Allen-Bradley, Siemens), HMIs, and SCADA systems.
• Strong knowledge of electrical systems, robotics, and industrial automation technologies.
• Experience with project management, including budgeting, scheduling, and resource allocation.
• Excellent problem-solving, analytical, and decision-making skills.
• Strong communication and interpersonal skills, with the ability to work effectively across multiple facilities and teams.
• Experience with food safety standards (e.g., FDA, USDA, HACCP) and regulatory requirements.
• Knowledge of lean manufacturing and Six Sigma methodologies.
• Familiarity with advanced manufacturing technologies, such as IIoT (Industrial Internet of Things) and machine learning.