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W3Global
Controls Engineer
Career Insights for Manufacturing Automation Engineer
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What they do
A Manufacturing Automation Engineer designs, programs and improves automated machinery and processes within a manufacturing environment. Are responsible for the design specifications, documentation and troubleshooting of the equipment. Often work within vehicle manufacturing and food processing plants, where robots or machines are used to perform specific functions.
$100,575 / year median in New Jersey
+10% projected growth
Job Description
Controls EngineerWe are seeking an experienced Controls Engineer to design, program, integrate, and commission automation systems for custom industrial equipment used in mixing, blending, drying, and material processing applications. This is a hands-on role involving projects from initial concept and engineering through startup, commissioning, and customer support.
Key ResponsibilitiesDesign and develop complete industrial control systems for custom machinery and integrated processing systems.
Program and troubleshoot PLC, HMI, and SCADA applications, including machine sequencing, process control, recipes, diagnostics, and data collection.
Develop control narratives, functional specifications, operating sequences, and standardized automation solutions.
Create and maintain I/O lists, electrical schematics, network architecture, panel layouts, instrumentation specifications, and alarm strategies.
Select and integrate PLCs, HMIs, VFDs, motors, sensors, load cells, instrumentation, safety devices, and other automation components.
Configure industrial networks and integrate third-party equipment using EtherNet/IP, PROFINET, Modbus TCP/RTU, OPC-UA, and related technologies.
Support electrical panel design and review drawings for applicable electrical and machine safety standards.
Work with mechanical engineering, project management, manufacturing, vendors, OEMs, and customers throughout project execution.
Participate in project planning, scheduling, budgeting, hardware/software selection, and controls deliverables.
Develop and conduct Factory Acceptance Testing (FAT) and Site Acceptance Testing (SAT).Lead equipment startup and commissioning at customer sites, including loop checks, functional testing, troubleshooting, and system validation.
Train customer operators and maintenance personnel following installation.
Provide ongoing technical support for troubleshooting, upgrades, modernization, and retrofit projects.
Contribute to automation standards, lessons learned, continuous improvement, remote diagnostics, and future controls platforms.
Participate in machine risk assessments and ensure safe operation in accordance with applicable electrical, machine safety, and industry standards.
Required QualificationsBachelor's degree in Electrical Engineering, Controls Engineering, Automation Engineering, Mechatronics, or a related engineering field.10+ years of experience in industrial automation, controls engineering, machine design, or manufacturing systems.
Background with custom machinery, OEM equipment, or process manufacturing environments.
Demonstrated experience taking controls projects from engineering/design through testing, startup, and commissioning.
Strong experience with:
Allen-Bradley ControlLogix and CompactLogixSiemens PLCsFactoryTalk View, WinCC, Ignition, or comparable HMI platformsIndustrial networking and communicationsVFDs and motion controlIndustrial instrumentationMachine safety and safeguardingAbility to read and produce electrical schematics and controls documentation.
Familiarity with SQL databases and industrial data acquisition/reporting systems.
Strong troubleshooting, analytical, project management, communication, and customer-facing skills.
Ability to manage multiple engineering projects and coordinate work across internal and external teams.
Willingness to travel approximately 40-50% for customer meetings, equipment installation, startup, commissioning, and service activities.
Preferred ExperiencePowder processing, blending, drying, pharmaceutical, food, chemical, additive manufacturing, or specialty materials equipment.
Batch process control systems.
UL 508A panel design requirements.
Validation documentation such as FAT, SAT, IQ, and OQ.Industry 4.0, remote monitoring/diagnostics, predictive maintenance, and connected manufacturing technologies.
What You'll Work OnYou will work on highly engineered, custom industrial equipment, partnering with engineering, manufacturing, vendors, and customers to deliver automation solutions from concept through successful installation and acceptance. The role offers opportunities to influence controls standards, support modernization projects, and take on increasing technical and project leadership responsibilities.
Key ResponsibilitiesDesign and develop complete industrial control systems for custom machinery and integrated processing systems.
Program and troubleshoot PLC, HMI, and SCADA applications, including machine sequencing, process control, recipes, diagnostics, and data collection.
Develop control narratives, functional specifications, operating sequences, and standardized automation solutions.
Create and maintain I/O lists, electrical schematics, network architecture, panel layouts, instrumentation specifications, and alarm strategies.
Select and integrate PLCs, HMIs, VFDs, motors, sensors, load cells, instrumentation, safety devices, and other automation components.
Configure industrial networks and integrate third-party equipment using EtherNet/IP, PROFINET, Modbus TCP/RTU, OPC-UA, and related technologies.
Support electrical panel design and review drawings for applicable electrical and machine safety standards.
Work with mechanical engineering, project management, manufacturing, vendors, OEMs, and customers throughout project execution.
Participate in project planning, scheduling, budgeting, hardware/software selection, and controls deliverables.
Develop and conduct Factory Acceptance Testing (FAT) and Site Acceptance Testing (SAT).Lead equipment startup and commissioning at customer sites, including loop checks, functional testing, troubleshooting, and system validation.
Train customer operators and maintenance personnel following installation.
Provide ongoing technical support for troubleshooting, upgrades, modernization, and retrofit projects.
Contribute to automation standards, lessons learned, continuous improvement, remote diagnostics, and future controls platforms.
Participate in machine risk assessments and ensure safe operation in accordance with applicable electrical, machine safety, and industry standards.
Required QualificationsBachelor's degree in Electrical Engineering, Controls Engineering, Automation Engineering, Mechatronics, or a related engineering field.10+ years of experience in industrial automation, controls engineering, machine design, or manufacturing systems.
Background with custom machinery, OEM equipment, or process manufacturing environments.
Demonstrated experience taking controls projects from engineering/design through testing, startup, and commissioning.
Strong experience with:
Allen-Bradley ControlLogix and CompactLogixSiemens PLCsFactoryTalk View, WinCC, Ignition, or comparable HMI platformsIndustrial networking and communicationsVFDs and motion controlIndustrial instrumentationMachine safety and safeguardingAbility to read and produce electrical schematics and controls documentation.
Familiarity with SQL databases and industrial data acquisition/reporting systems.
Strong troubleshooting, analytical, project management, communication, and customer-facing skills.
Ability to manage multiple engineering projects and coordinate work across internal and external teams.
Willingness to travel approximately 40-50% for customer meetings, equipment installation, startup, commissioning, and service activities.
Preferred ExperiencePowder processing, blending, drying, pharmaceutical, food, chemical, additive manufacturing, or specialty materials equipment.
Batch process control systems.
UL 508A panel design requirements.
Validation documentation such as FAT, SAT, IQ, and OQ.Industry 4.0, remote monitoring/diagnostics, predictive maintenance, and connected manufacturing technologies.
What You'll Work OnYou will work on highly engineered, custom industrial equipment, partnering with engineering, manufacturing, vendors, and customers to deliver automation solutions from concept through successful installation and acceptance. The role offers opportunities to influence controls standards, support modernization projects, and take on increasing technical and project leadership responsibilities.