Automation/Controls Engineer

GEON Performance Solutions; Terre Haute (IN); On-site; USD 85,000 - 110,000; Full time

Job summary

GEON Performance Solutions is seeking an Automation/Controls Engineer to lead automation and reliability initiatives across manufacturing operations. The role focuses on developing, implementing, and sustaining automated control systems to improve safety, quality, and efficiency.

The engineer will work cross-functionally to reduce downtime, optimize equipment performance, and support maintenance and project activities within a dynamic production environment.

Qualifications

• Bachelor’s degree in engineering or equivalent technical field.
• Minimum 3 years in a manufacturing environment (process, batch, or continuous preferred).
• Proven track record of reducing equipment downtime through proactive monitoring, controls optimization, and process improvement.
• Hands-on experience with PLC programming (Allen-Bradley, Siemens, Schneider, etc.), HMI development, and system integration.
• Experience with process instrumentation (sensors, flow, level, temp, pressure).
• Familiarity with CMMS platforms (Emaint) for scheduling and documentation; knowledge of safety circuit design and risk assessments.
• Understanding of ISO, FDA, GMP depending on plant context.
• Experience with control panel design and electrical schematic review.
• Proficiency in Microsoft Office and technical documentation tools.

Responsibilities

• Evaluate and improve existing automation systems to enhance throughput, efficiency, and quality.
• Identify process inefficiencies and lead efforts to streamline workflows and reduce cycle times.
• Support Lean/Six Sigma initiatives and drive structured problem-solving efforts.
• Develop, program, and troubleshoot PLC-based control systems and maintain HMI interfaces.
• Ensure system reliability by maintaining and upgrading legacy automation infrastructure.
• Serve as CMMS power user, managing automation-related maintenance plans and documentation.
• Lead small-to-mid-scale capital projects involving control system upgrades and new equipment integration.
• Provide technical training and troubleshooting guidance to technicians and operators.
• Communicate automation changes across engineering, production, and maintenance teams.
• Support change management with updated SOPs and process validations.

Skills

PLC programming

HMI development

Industrial control systems

Process instrumentation

CMMS (Emaint)

Safety circuit design

Root cause analysis

Lean Six Sigma

Cross-functional collaboration

Technical communication

Documentation

Education

Bachelor’s Degree in Electrical/Mechanical/Industrial Engineering

Tools

Ignition Perspective

Allen-Bradley

Siemens

Schneider Electric

CMMS (Emaint)

Job description

Automation/Controls Engineer

Reporting To Position: Engineering Manager

Summary

We are seeking a results-driven Automation Engineer to lead process automation and reliability initiatives that improve safety, quality, and operational efficiency across our manufacturing operations. This role will work cross-functionally to develop, implement, and sustain automated control systems and process improvements that reduce downtime and optimize equipment performance.

Experience & Education

• Bachelor’s Degree in Electrical, Mechanical, or Industrial Engineering, or equivalent technical field.
• Minimum 3 years of experience within a manufacturing environment (process, batch, or continuous preferred).
• Proven track record of:
  • Reducing equipment downtime through proactive monitoring, controls optimization, and process improvement.
  • Applying reliability-centered maintenance (RCM) strategies, including but not restricted to condition-based monitoring.
• Hands‑on experience with:
  • PLC programming (Allen-Bradley, Siemens, Schneider, etc.)
  • HMI development and system integration
  • Industrial control system design and troubleshooting
  • Process instrumentation (sensors, flow, level, temp, pressure, etc.)
• Preferred Qualifications:
  • Familiarity with CMMS platforms (Emaint, etc.) for scheduling and documentation
  • Knowledge of safety circuit design, lockout/tagout procedures, and risk assessments
  • Understanding of regulated manufacturing standards (e.g., ISO, FDA, GMP depending on plant context)
  • Experience with control panel design and electrical schematic review
  • Proficiency in Microsoft Office (Excel, Word, Outlook) and technical documentation tools
• Analytical Thinking & Root Cause Analysis
• Process Improvement & Documentation
• Technical Communication
• Cross‑Functional Collaboration
• Self‑Motivation & Accountability
• Adaptability & Continuous Learning

Key Responsibilities

• Process Optimization & Improvement:
  • Evaluate and improve existing automation systems to enhance throughput, efficiency, and quality.
  • Identify process inefficiencies and lead efforts to streamline workflows and reduce cycle times.
  • Support Lean/Six Sigma initiatives and drive structured problem-solving efforts.
• Automation Systems Support:
  • Develop, program, and troubleshoot PLC‑based control systems (Allen‑Bradley, Siemens, Schneider, etc.).
  • Design and maintain HMI interfaces and control architecture documentation (Ignition Perspective).
  • Ensure system reliability by maintaining and upgrading legacy automation infrastructure.
  • Serve as the primary contact for IT, ensuring seamless communication and collaboration between the plant's automation systems and IT infrastructure to support operational efficiency and troubleshooting.
• Reliability & Maintenance Engineering:
  • Lead root cause analysis of recurring equipment failures and implement permanent corrective actions.
  • Collaborate with maintenance and production teams to develop preventive and predictive maintenance strategies.
  • Serve as a CMMS (Emaint) power user, managing automation‑related maintenance plans and documentation.
• Project Management:
  • Lead small‑to‑mid‑scale capital projects involving control system upgrades, line modifications, and new equipment integration.
  • Develop project scopes, timelines, budgets, and provide technical support during startup and commissioning phases.
• Provide technical training and troubleshooting guidance to technicians and operators.
• Communicate automation changes and improvements effectively across engineering, production, and maintenance teams.
• Support change management efforts including documentation updates, SOPs, and process validations.

Work Environment & Physical Demands

• Ability to stand, walk, kneel, and lift up to 50 lbs. in a production environment
• Occasional exposure to heat, noise, mechanical equipment, and airborne particles
• May require occasional off‑shift or weekend support for project execution or troubleshooting

Travel Requirements

• Occasional travel (Approx. 10%) may be required for:
  • Vendor or OEM visits for equipment specification or troubleshooting
  • Off‑site training or professional development
  • Corporate meetings or cross‑plant support (if part of a multi‑site operations)