Controls Engineer

Job Description

This ongoing consulting role supporting a leading pharmaceutical manufacturing operation. The Controls Engineer will lead the design, development, and implementation of control system upgrades for batch processing equipment, focusing on PLC programming, HMI development, load cell integration, and commissioning support. Working closely with operations, maintenance, controls, and project teams, this role develops scalable automation solutions on Allen-Bradley platforms while ensuring strict adherence to safety, quality, and manufacturing standards. The position offers hands-on technical ownership across the full project lifecycle, from concept and design through commissioning and startup, with strong opportunities for professional growth in a consulting environment.

Responsibilities

·         Lead electrical and controls design activities for manufacturing control system upgrades, with a focus on batch processing equipment.

·         Identify and integrate load cells, summing boxes, and related instrumentation into existing and new automation architectures.

·         Develop PLC logic using Allen-Bradley ControlLogix and CompactLogix platforms to support reliable and scalable manufacturing operations.

·         Design and configure HMI screens to provide intuitive operator interfaces using tools such as FactoryTalk View SE/ME.

·         Specify controls hardware and industrial instrumentation to meet project requirements, standards, and performance objectives.

·         Develop detailed electrical schematics, I/O documentation, and integration drawings to support installation and commissioning.

·         Support the creation and maintenance of AutoCAD Electrical and AutoCAD P&ID drawings for process and control systems.

·         Create comprehensive integration, testing, commissioning, and startup plans to ensure smooth deployment of new control systems.

·         Support Factory Acceptance Testing (FAT), Site Acceptance Testing (SAT), startup, and troubleshooting activities at customer sites.

·         Develop complete PLC and HMI documentation packages, including functional specifications, configuration details, and operating procedures.

·         Collaborate closely with project stakeholders across Operations, Maintenance, Quality, Process Engineering, and Project Management to align automation solutions with business and production needs.

·         Independently manage engineering tasks from concept development through commissioning and startup while meeting project schedules and deliverable commitments.

·         Troubleshoot complex equipment and control system issues in manufacturing environments, providing practical solutions to improve reliability and performance.

·         Prepare and maintain technical documentation, engineering packages, specifications, and design deliverables with high accuracy and attention to detail.

·         Contribute to front-end engineering design (FEED) activities, particularly related to Siemens and other automation platforms when required.

·         Support continuous improvement initiatives by identifying opportunities to enhance safety, quality, and operational efficiency through automation.

·         Participate in site assessments, design reviews, vendor coordination, and project meetings, including during periods of increased activity for startup and commissioning.

Essential Skills

·         Bachelor’s degree in Electrical Engineering, Electrical Engineering Technology, Controls Engineering, Automation Engineering, or a related technical discipline.

·         5–10 years of progressive engineering experience supporting industrial manufacturing, process controls, automation, or capital project execution.

·         Proven ability to independently manage engineering tasks from concept development through commissioning and startup.

·         Strong understanding of electrical systems, industrial controls, instrumentation, and automation architectures.

·         Hands-on experience with PLC and HMI development in manufacturing environments.

·         Demonstrated ability to troubleshoot complex equipment and control system issues in a manufacturing setting.

·         Experience developing technical documentation, engineering packages, specifications, and design deliverables.

·         Ability to read and interpret electrical drawings and P&IDs.

·         Articulated experience with Allen-Bradley ControlLogix and/or CompactLogix platforms.

·         Proficiency with Studio 5000/RSLogix 5000 for PLC programming and configuration.

·         Experience with FactoryTalk View SE/ME for HMI development and configuration.

·         Proficiency with AutoCAD Electrical and AutoCAD P&ID for control and process drawings.

·         Experience with industrial instrumentation and controls, including load cells and summing boxes.

·         Knowledge of applicable electrical codes, industry standards, and engineering best practices.

·         Strong analytical, problem-solving, and decision-making skills.

·         Ability to effectively communicate technical concepts to both technical and non-technical stakeholders.

·         Proficiency with Microsoft Office applications, including Excel, Word, Outlook, and Teams.

·         Strong organizational skills with attention to detail and documentation accuracy.

·         Ability to work effectively in both independent and team-based environments.

·         Demonstrated commitment to safety, quality, and continuous improvement initiatives.

·         Willingness to travel and support field activities, commissioning efforts, and startup activities as required.

Additional Skills & Qualifications

·         Experience working within cross-functional teams, including Operations, Maintenance, Quality, Process Engineering, and Project Management.

·         Front-end engineering design (FEED) experience, including exposure to Siemens automation technologies.

·         Experience in pharmaceutical, food processing, or batch manufacturing environments.

·         Direct experience with commissioning, startup, and acceptance testing (FAT and SAT) for industrial automation projects.

·         Industrial manufacturing and process controls that supports large-scale automation initiatives.

·         Ability to manage multiple priorities while meeting project schedules and deliverable commitments.

·         Experience collaborating with vendors and external partners during design, integration, and commissioning phases.

·         Interest in consulting-style work that offers exposure to diverse projects and modern Allen-Bradley automation technologies.

·         Motivation to solve complex engineering challenges, drive measurable production improvements, and accelerate professional growth