Controls Engineer

• ◆Lead hands-on programming, debugging, and commissioning of Allen-Bradley/Rockwell, Siemens, and other industrial control hardware. Apply internal standards across grinding, wire saw, EDM, tumbling, coating, magnetization, and in-line inspection equipment.
• ◆Own the integration and commissioning of robot cells(Fanuc, ABB, Kuka) - cell layout review, end-of-arm tooling, PLC-to-robot handshaking, machine vision, and coordinated motion with indexing conveyors, rotary tables, and servo feed systems.
• ◆Execute task-based risk assessments to ISO 10218-1/-2, ISO/TS 15066, and ANSI/RIA R15.06; specify and validate safety functions — safe soft limits and zone monitoring, enabling devices, guard interlocks, and safety-rated stops — and demonstrate each one at Factory Acceptance Test rather than discovering it on site.
• ◆Configure and maintain communications between PLCs, robots, CNC-class machine controls, and the site SCADA/MES layer, including tag mapping, alarming, and data acquisition.
• ◆Review vendor electrical schematics, controls architectures, robot programs, and PLC/HMI logic. Lead controls Factory Acceptance Tests (FATs) and Site Acceptance Tests (SATs) to ensure full compliance with functional and safety requirements.
• ◆Integrate dimensional and defect inspection, profilometry, and analytical test instrumentation into cell control and the plant data layer - measurement-to-reject interlocks, SPC data flow, and the disposition logic.
• ◆Serve as the first-line, hands-on responder for diagnosing complex automation issues involving robots, networks, motion systems, instrumentation, and industrial communication protocols - on both the new facility and the running pilot.

Deliverables You Will Develop, Review, or Support

• ◆PLC code architecture, robot programs and safety zone configurations, HMI screens, vision inspection programs, tag databases, network lists, and system backups.
• ◆Robot cell and machine risk assessments, safety function specifications with required performance levels, interlock and guarding logic, and safety-rated PFMEA inputs.
• ◆Cell layouts, controls and network topology layouts, station cycle times, sequence diagrams, and automation simulations.
• ◆Electrical schematics, pneumatic drawings, controls panel layouts, end-of-arm tooling interface drawings, and industrial network architecture.
• ◆Calibration procedures, I/O lists, instrumentation documentation, robot mastering and maintenance procedures, and controls hardware maintenance manuals.

and tasks outlined are not exhaustive and may change as determined by the needs of the business

• ✓Bachelor’s or Master’s degree in Electrical Engineering, Automation Engineering, Mechatronics, or a related field with 4+ years of direct industrial automation and controls engineering experience.
• ✓Strong hands-on experience programming and commissioning Allen-Bradley/Rockwell, SIemens PLCs and HMIs, including safety PLCs such as GuardLogix.
• ✓Hands-on experience integrating multi-axis robots – FANUC, ABB, and/or KUKA - including teaching, program review, PLC handshaking, and safety zone configuration.
• ✓Grinding, wire saw, EDM, or lapping equipment; mass finishing and deburring lines; conveyorized coating and cure ovens.
• ✓Servos, VFDs, indexing conveyors, rotary tables, and automated feed systems; proficiency with Ethernet/IP, OPC UA, and similar industrial communication standards.
• ✓Demonstrated FAT and SAT participation — you have tested machines at vendor shops and commissioned them in the field — with structured troubleshooting, disciplined change control, and honest escalation.

Must be a U.S. Person due to required access to U.S. export-controlled information or facilities