Job Title:

Senior Control Systems Engineer Location:

US Beverage Packers

LLC FLSA

Status:

Hourly Sponsorship may be considered for qualified candidates who meet the requirements of the position. Job Summary The Senior Control Systems Engineer is responsible for designing, developing, implementing, troubleshooting, and optimizing industrial automation and control systems across the Company's manufacturing and production facilities. This position provides advanced technical expertise in programmable logic controllers (PLCs), human-machine interfaces (HMIs), industrial networks, robotics, vision systems, and automated material handling equipment to improve production efficiency, equipment reliability, and operational performance. This position leads automation projects from initial planning and system design through implementation, commissioning, and optimization. The Senior Control Systems Engineer serves as a primary technical resource for engineering, maintenance, and production teams, providing high-level troubleshooting support, developing control system improvements, and ensuring seamless integration of new equipment into existing production lines. The role also leads and mentors junior engineers and technicians, supports automated packaging lines and robotic systems at the Edison facility, and oversees technical improvements to automated storage and retrieval systems (ASRS). The position requires collaboration with senior leadership and cross-functional teams to identify operational needs, implement strategic upgrades, minimize downtime, and support continuous improvement initiatives. Core Competencies & Responsibilities 1. Safety & Compliance Follow all Company safety policies, procedures, PPE requirements, and applicable regulatory guidelines when working with industrial automation, electrical systems, machinery, and robotics. Identify, report, and help resolve unsafe conditions associated with automated equipment and control systems. Follow established safety procedures when troubleshooting, modifying, testing, and commissioning control systems and production machinery. Comply with fall protection requirements when working at elevated heights, including the use of required fall arrest equipment. Support safe equipment operation through control system design, risk identification, and implementation of appropriate safeguards. 2. Quality & Standards Ensure automation and control systems operate consistently and meet established production, quality, and operational requirements. Develop, test, and validate PLC programs, HMI applications, and control system modifications to ensure accuracy, reliability, and functionality. Lead the integration and optimization of industrial vision systems, sensors, and automated product sorting systems to support quality control requirements. Investigate recurring process control issues and implement corrective actions to improve system performance and product quality. Maintain accurate technical documentation, testing results, system configurations, and operational manuals to support compliance, consistency, and knowledge transfer. 3. Productivity & Operational Excellence Design, develop, and implement PLC programming strategies using RSLogix 500, Studio 5000, and Rockwell Automation platforms to integrate new machinery and improve existing production lines. Lead automation projects from initial planning and needs assessment through design, implementation, commissioning, and optimization. Evaluate existing production systems through needs analysis, gap assessments, and process evaluations to identify opportunities for automation upgrades and improved operational performance. Optimize machine handling, automated packaging lines, material handling systems, and production equipment to maximize efficiency, reliability, and utilization. Recommend and implement control system upgrades, software enhancements, and process improvements to reduce downtime and support long-term operational goals. Troubleshoot and optimize automated storage and retrieval systems (ASRS), including automated pallet storage and retrieval solutions. Support continuous improvement initiatives by identifying root causes of equipment issues and implementing sustainable technical solutions. 4. Communication & Teamwork Collaborate with Engineering, Maintenance, Production, and other cross-functional teams to support equipment reliability and manufacturing objectives. Serve as a primary technical resource for complex automation and process control issues, providing advanced troubleshooting guidance to maintenance teams. Communicate project progress, technical findings, system limitations, operational risks, and recommended solutions to senior leadership and relevant stakeholders. Coordinate automation projects involving internal teams, equipment suppliers, and other technical resources to support successful implementation. Provide technical support for the Edison automated packaging lines and robotic systems as needed to maintain reliable production operations. Maintain clear communication during equipment upgrades, system modifications, troubleshooting activities, and production disruptions. 5.

Technical / Job

-Specific Skills Design, program, troubleshoot, and modify PLC-based control systems using Allen-Bradley ControlLogix, CompactLogix, RSLogix 500, Studio 5000, and other applicable Rockwell Automation platforms. Develop and maintain HMI applications using FactoryTalk View Studio to provide effective operator interfaces and support production monitoring and control. Configure, troubleshoot, and optimize Allen-Bradley PowerFlex variable frequency drives (VFDs) and associated motor control systems. Support the integration of PLCs and automation systems with Supervisory Control and Data Acquisition (SCADA), Human-Machine Interface (HMI), and Manufacturing Execution System (MES) platforms. Troubleshoot and modify industrial communication networks, including Ethernet, Profibus, and AS-Interface (AS-i). Provide technical expertise in FANUC robotics, including robot operation, teach pendant programming, parameter modification, and re-teaching robot positions as required. Lead the development of control system programs and HMI applications to support new equipment installations, production improvements, and changing operational requirements. Troubleshoot and optimize automated material handling systems, packaging equipment, robotic applications, and ASRS technology. Interpret, review, and modify Piping and Instrumentation Diagrams (P&IDs), electrical schematics, control drawings, and related technical documentation. Diagnose complex automation faults, identify root causes, implement corrective actions, and document software changes and system improvements. Lead technical training for production leadership, machine operators, maintenance personnel, and junior engineers to improve system understanding and reduce equipment downtime. 6. Professionalism & Growth Demonstrate strong technical judgment, professionalism, accountability, and a commitment to continuous improvement. Lead and mentor junior engineers and technicians in control system design, PLC programming, HMI development, troubleshooting, and equipment optimization. Provide technical guidance and training to maintenance and production personnel to strengthen internal automation capabilities. Manage multiple concurrent automation projects while maintaining project schedules, coordinating resources, and meeting operational priorities. Stay informed of emerging automation technologies, industrial control platforms, and equipment improvements relevant to manufacturing operations. Develop and maintain standardized programming practices, technical documentation, and troubleshooting procedures to support long-term system reliability and knowledge transfer.

Qualifications Education:

Bachelor's degree in Electrical Engineering, Automation Engineering, or a related field required.

Experience:

Minimum of 3 years of experience in the position offered or as a Control Systems Engineer, with a focus on PLC programming, HMI development, and industrial automation systems.

PLC Programming:

Experience with Allen-Bradley ControlLogix, CompactLogix, RSLogix 500, Studio 5000, and Rockwell Automation platforms.

Control Systems:

Experience configuring and troubleshooting Allen-Bradley PowerFlex VFDs and integrating PLCs with SCADA, HMI, and MES platforms.

Robotics & Vision Systems:

Experience with FANUC robotics, robot programming and troubleshooting, industrial vision systems, and sensors used in automated production and quality control.

Project Management:

Experience leading automation projects from planning and design through implementation, commissioning, and optimization, including coordinating project schedules, resources, and technical teams.

Leadership:

Experience mentoring junior engineers or technicians and collaborating with engineering, maintenance, production, and senior leadership.

Technical Software:

Experience using RSLogix, Studio 5000, FactoryTalk View Studio, and related industrial automation tools.

Additional Requirements:

Ability to manage multiple projects in a fast-paced manufacturing environment and work at elevated heights of at least five stories while wearing required fall protection equipment. Physical & Environmental Requirements Work in an active manufacturing environment with high-speed production lines, automated machinery, industrial equipment, and varying noise levels. Work around electrical systems, control panels, robotics, automated material handling equipment, and production machinery while following applicable safety procedures. Access elevated work areas, including heights of at least five stories, when required, using approved fall protection equipment and procedures. Stand, walk, bend, reach, and perform other physical activities necessary to inspect, troubleshoot, test, and support industrial equipment. Use computers, engineering software, diagnostic tools, and technical instruments to develop, test, and maintain control systems. Work in a fast-paced environment that may require responding to urgent equipment issues, production interruptions, and competing project priorities. Disclaimer This job description is intended to describe the general nature and level of work performed by employees assigned to this position. It is not designed to contain or be interpreted as an exhaustive list of all duties, responsibilities, and qualifications required. Additional responsibilities may be assigned based on business needs.

Pay:

$35.00 - $45.00 per hour Expected hours: 40.0 per week

Benefits:

401(k) Dental insurance Referral program

Work Location:

In person