Sr Controls & Automation Engineer

Senior Controls & Automation Engineer

LocationColumbus, Georgia.

Compensation Base Salary: $100,000 to $140,000 USD (with up to 10% bonus potential) + Paid Relocation

TheSenior Controls & Automation Engineeris a critical technical leader focused on theelectrical systems, controls infrastructure, and advanced automationwithin a high-volume manufacturing facility. This role is a key driver for the plant’s modernization strategy, including a significant multi-million dollar capital expenditure project aimed at upgrading and replacing obsolete controls (e.g., an ABB system divorce and new production equipment).

As one of the plant's dedicated controls resources, you will serve as the primary subject matter expert, taking ownership of both low and high-voltage electrical/controls infrastructure. This position requires deep technical expertise in PLCs, HMIs, and drives, coupled with the ability to lead complex projects, troubleshoot sophisticated issues, and ensure sustained operational success across a 24/7 manufacturing environment.

Automation, Modernization & Project Leadership

  • Capital Project Lead:Serve as the Lead Electrical/Controls Engineer on major or complex capital projects, often exceeding $1M in scope, responsible for planning, execution, and timely milestone achievement.

  • System Migration:Proactively develop and execute plans for the migration away fromobsolete or stranded equipment and control systems, ensuring high reliability and continuous production capacity.

  • Standardization:Drive thestandardization and simplificationof common electrical parts, control systems, and programming logic across the plant to improve maintainability.

  • Efficiency:Identify and implement innovativeautomation solutionsto increase manufacturing efficiency, throughput, and product quality.

  • Robotics & Drives:Manage, program, and troubleshoot robotic platforms (e.g., ABB, Fanuc) and complexVariable Frequency Drive (VFD) and servo applications.

Controls & Infrastructure Ownership

  • Core Engineering:Maintain, program, and troubleshoot all plant electrical and controls systems, demonstrating high proficiency withAllen-Bradley PLC and HMI applications(including network communications).

  • Electrical Infrastructure:Act as the plant expert and owner for bothlow and high-voltage electrical infrastructure, ensuring safe and reliable operation.

  • Documentation:Ensure alllegacy control systems are documented, and meticulously create and maintain documentation for all new or modified systems and processes.

  • Quality & Safety:Drive continuous improvement in product quality by linking process capability to controls performance, and support safety and environmental compliance efforts.

Operational Support & Compliance

  • Advanced Troubleshooting:Provide high-level daily support for manufacturing operations, diagnosing and resolving complex electrical and control system failures to maintain safety and production effectiveness.

  • Safety Compliance:Ensure strict application of theNFPA 70E Standard for Electrical Safety in the Workplacerelated to arc flash energy and shock hazards.

  • Cross-Functional Support:Work with the Process Engineering team and provide support to other departments, including assisting IT with basic plant infrastructure and HR/Safety with security access and camera systems.

Required Qualifications

Technical & Educational Requirements

  • Education:Bachelor's degree inElectrical EngineeringorElectrical Engineering Technology.

  • Experience:A minimum of3 yearsof experience incontrol systems engineeringin a continuous and/or discrete manufacturing environment.

  • Controls Proficiency:Expert-level proficiency withAllen-Bradley PLC and HMI programming(including ladder logic, structured text, and communication protocols) and system design.

  • Safety Compliance:Demonstrated knowledge and ability to apply theNFPA 70E Standard for Electrical Safety.

  • Systems Knowledge:Strong working knowledge and understanding ofMechanical Systemsas they relate to control implementation.

Preferred Qualifications

  • Experience withFanuc RoboticsorCognex Vision Systems.

  • Experience withWonderwarecontrol software platforms.

  • Experience withAutoCAD or Visiosoftware for drafting control schematics.

  • Knowledge ofLean and Six Sigmaprinciples or experience with ISO/structured business operating models.

  • Experience with an ERP system (e.g., SAP).

Working Conditions

This role is primarily based on traditional workdays (Monday-Friday, 6:30 AM to 4:30 PM), but requiresflexibility to work occasional alternate schedulesas necessary to manage high-priority projects, process startups, and critical maintenance windows.

  • Work Environment:The job is located in an industrial, manufacturing plant. Approximately 30% of time is spent on the plant floor working around heavy machinery, high noise levels, and mobile equipment.

  • Physical Demands:Requires ability to access all work areas (e.g., climbing ladders, negotiating catwalks up to 50 feet), lift up to 50 lbs., and work in environments that arenot climate controlled(may be extremely hot/humid or cold).

  • PPE:Required to wear standard Personal Protective Equipment (PPE) including safety-toed shoes, hearing protection, and eye protection, with occasional requirements for dust masks or respirators.