Principal Controls Engineer

We are looking for a Principal Controls Engineer who will serve as the senior technical authority for industrial automation and control systems across multiple manufacturing facilities. This role is responsible for defining, governing, and continuously improving the controls architecture, standards, and best practices that support safe, reliable, and efficient flooring manufacturing operations.

The Principal Controls Engineer leads the design and implementation of complex automation systems for capital projects, major upgrades, and brownfield improvements while providing technical leadership, mentorship, and escalation support to controls engineers, technicians, and integrators. This position partners closely with Engineering, Manufacturing, Maintenance, IT, and external vendors to ensure automation solutions align with business objectives, cybersecurity standards, and long-term operational sustainability.

• ◆Technical Authority & Architecture Ownership:
• ◆Serve as the principal technical authority for PLC, HMI, industrial networking, and data integration platforms across multiple manufacturing plants.
• ◆Define, maintain, and enforce enterprise-wide standards for control system architecture, programming practices, HMI design, and documentation.
• ◆Evaluate and approve automation platforms, system designs, and technology roadmaps to ensure scalability, reliability, and long-term supportability.
• ◆Control System Design & Capital Projects:
• ◆Lead the controls scope for capital projects, equipment installations, and major process upgrades from concept through commissioning and handover.
• ◆Develop functional specifications, control philosophies, network architecture, and system layouts for complex manufacturing systems.
• ◆Provide technical leadership during commissioning, startup, and production ramp-up to ensure stable and predictable system performance.
• ◆PLC, HMI & Software Strategy:
• ◆Write, debug, and modify PLC (Programmable Logic Controller) code for control systems to optimize production efficiency and quality.
• ◆Create Human-Machine Interface (HMI) applications for monitoring and controlling machinery.
• ◆Oversee the development, review, and optimization of PLC programs using platforms such as Allen-Bradley and Siemens.
• ◆Establish structured programming methodologies to improve code quality, reusability, and long-term maintainability.
• ◆Define HMI standards focused on usability, operator effectiveness, and consistent visualization across manufacturing lines.
• ◆Manufacturing Data & Integration:
• ◆Architect and support data collection systems, historians, and integration with manufacturing and business systems.
• ◆Enable data-driven decision-making by supporting OEE, downtime analysis, quality metrics, and performance monitoring.
• ◆Collaborate with cross-functional teams to integrate control systems with other manufacturing equipment and systems, ensuring seamless production flow.
• ◆Troubleshooting & Reliability Leadership:
• ◆Act as the highest-level escalation point for complex controls and automation-related issues impacting safety, quality, or production.
• ◆Lead advanced root cause analysis efforts and implement permanent corrective actions to eliminate chronic equipment issues.
• ◆Drive proactive reliability improvements through system redesign, standardization, and failure prevention strategies.
• ◆Documentation:
• ◆Maintain comprehensive documentation of control system designs, modifications, and troubleshooting procedures.
• ◆Safety & Compliance:
• ◆Ensure all control systems comply with applicable safety standards, regulatory requirements, and corporate policies.
• ◆Support machine safety initiatives, risk assessments, and validation activities to maintain a safe manufacturing environment.
• ◆Champion safe automation design principles throughout project and operational activities.
• ◆Mentorship & Technical Leadership:
• ◆Mentor and guide controls engineers and technicians through technical coaching, design reviews, and knowledge sharing.
• ◆Provide technical oversight for system integrators and OEMs to ensure adherence to company standards and expectations.
• ◆Influence continuous improvement culture through technical leadership rather than direct authority.
• ◆Continuous Improvement:
• ◆Identify and implement automation-driven opportunities to improve throughput, quality, uptime, and operating cost.
• ◆Support long-term automation strategy and technology roadmaps aligned with business growth and modernization goals.
• ◆Drive standardization and replication of best practices across facilities.

• ✓Bachelor of Science in Electrical Engineering, Controls Engineering, or a related technical discipline (or equivalent experience).
• ✓10+ years of experience designing, implementing, and supporting industrial automation systems in a manufacturing environment.
• ✓Extensive experience with Allen-Bradley and Siemens PLC platforms.
• ✓Strong expertise in HMI development, industrial networking, and control system architecture.
• ✓Working knowledge of electrical schematics, motor controls, VFDs, and industrial communication protocols.
• ✓Demonstrated ability to lead technical decisions, influence stakeholders, and mentor less experienced engineers.
• ✓Strong problem-solving skills with the ability to diagnose complex system-level issues.
• ✓Excellent communication skills and the ability to collaborate across engineering, manufacturing, maintenance, and IT functions.

• ✓Certification in PLC programming or industrial automation.
• ✓Experience supporting high-speed, high-volume manufacturing operations, preferably in the flooring or building products industry
• ✓Multi-site manufacturing support experience.
• ✓Experience with data historians, manufacturing analytics, MES/MOM systems, or digital transformation initiatives.
• ✓Formal