Associate Lead Engineer Controls

Barry-Wehmiller; Chennai District; On-site; INR 1,800,000 - 3,200,000; Full time

Job summary

Barry-Wehmiller seeks a Lead Controls Engineer to develop high-level controls and automation for OEM machinery, focusing on motion programming, PLCs, HMIs, and data collection. You will collaborate across teams to design, implement, and document control systems for form/fill/seal packaging equipment.

The role requires extensive experience in Allen-Bradley platforms, safety standards, and strong problem-solving, communication, and travel readiness for domestic and international projects.

Qualifications

• Bachelor’s degree in Electronics & Communication / Electrical & Electronics / Mechatronics or related field.
• Minimum 10 years of experience in controls/automation engineering in industrial manufacturing equipment.
• Experience with motion control and system integration in industrial environments.
• Experience with OEMs in packaging/manufacturing sectors preferred.
• Willingness to travel up to 20% domestically/internationally.

Responsibilities

• High-level programming of PLCs, HMIs, motion controllers and data collection systems.
• Maintain and develop advanced control software for packaging machinery and product feeds.
• Design and implement automation solutions with project documentation.
• Utilize Rockwell (AB) as primary platform; other suppliers as needed.
• Provide guidance to cross-functional teams and perform diagnostics/testing.

Skills

Allen-Bradley PLCs

HMI design

Motion control

Industrial networks

Safety engineering

Documentation

Education

Bachelor’s in ECE/EEE/Mechatronics

Tools

Studio 5000

FactoryTalk

AutoCAD

Job description

The Lead Controls Engineer will develop high-level controls and automation solutions for our OEM industrial machinery / Special Purpose Machines (SPM) using PLC, HMI, motion controllers, data collection, communication devices and all associated software with an emphasis on motion programming and emerging technologies. The ideal candidate must work well in a team environment and is proficient at building relationships, developing high-level control systems and capable of troubleshooting in high-intensity environments. This role actively engages in our Lean journey by building and acting on continuous improvement and development opportunities and encourages others to discover, develop and apply their talents, enabling them to reach their full potential.

Key Responsibilities:

• High-level programming of PLCs, HMIs, motion controllers, data collection systems and other associated devices to develop and support new and existing product lines.
• Maintain existing and develop new, advanced electrical control software/systems for our vertical and horizontal form/fill/seal packaging machinery and product feed systems.
• Create, design and implement automation and control systems along with associated project documentation and drawings to meet legacy, current and future machinery requirements.
• Use available, off-the-shelf control hardware and software components for machine functionality, safety and motion. Primary solution is Rockwell (AB) but may include B&R, Siemens or various other suppliers.
• Develop and maintain comprehensive documentation for software diagnostics, information systems, data collection and communication for all product lines and other peripheral equipment.
• Act as a high-level specialist, providing guidance in a team environment to production assembly, service, engineering teams and system suppliers to furnish information and documentation about software controls; perform check-out and correction of control system hardware and software as needed.
• Perform complex troubleshooting/diagnostics in plant, or remotely, in partnership with internal and external customers.

Mandatory Skills:

• Solid understanding and experience with machine safety applications, electrical power distribution, industrial control panel design and fabrication. (UL508A)
• Experience creating and designing with Allen-Bradley (ControlLogix, CompactLogix, PLC5, SLC500) PLCs, PanelView/PanelView Plus HMIs, Industrial Communication Networks (Ethernet, Ethernet I/P, Device Net, DH+, etc.) and associated programming software (Studio 5000, FactoryTalk, etc.).
• Solid understanding and experience developing engineering documentation such as schematics, machine specifications, standard operating procedures and training documentation (ACAD).
• Demonstrated ability to understand strategic goals and implement technical solutions to achieve these goals.
• Equipment Testing / Commissioning experience.
• Positive attitude with excellent communication, organizational, and interpersonal skills along with strong written and verbal technical communication skills.
• Ability to successfully work across all levels of the organization.
• Excellent attention to detail and demonstrated problem-solving ability.
• Ability and willingness to travel, which may include international on occasion - approximately 20% travel.
• Must have a valid driver’s license, good driving record and the ability to obtain a passport.

Soft Skills:

• Clear and professional communication
• Strong interpersonal skills to effectively communicate with team abroad
• Strong teamwork and coordination with cross-functional teams
• Ability to work independently and take ownership
• Analytical thinking and structured problem solving
• Flexibility to adapt to changing project needs undefined

Education and Experience:

• Bachelor’s degree in Electronics & Communication / Electrical & Electronics / Mechatronics engineering or related field from an accredited college or university.
• Minimum 10 years of experience in a controls or automation engineering type working on/with industrial manufacturing equipment.
• Focus on motion control, automated processes and system integration in an industrial manufacturing environment such as Food, Consumer Products, Pharmaceutical or similar.
• Experience with OEMs in paper, packaging, printing, or converting and machine building division is preferred

Travel:

Occasional domestic and/or global travel may be required for this position up to 20%.