Controls Engineer

Feldmeier Equipment Inc; City of Syracuse (NY); On-site; USD 90,000 - 120,000; Full time

Job summary

Feldmeier Equipment Inc is seeking a Controls Engineer to join our Manufacturing Engineering team. You will reverse engineer legacy systems, develop and maintain PLC and HMI programs, and support new equipment installations across our facilities.

The role combines hands-on troubleshooting with engineering design to improve production, quality, safety, and efficiency. You will work with maintenance and production teams to implement process improvements, analyze performance data, and develop

Qualifications

• Requires a Bachelor's degree in Electrical/Controls/Mechatronics engineering or related field.
• Minimum 3 years in industrial controls, automation, or manufacturing engineering.
• Experience programming and troubleshooting PLC systems; Allen-Bradley experience preferred.
• Experience with HMI development and industrial networking.
• Strong reading of electrical schematics and technical documentation.

Responsibilities

• Reverse engineer existing equipment to document and improve functionality.
• Troubleshoot PLC, HMI, servo, VFD, and automation issues on production lines.
• Design, modify, and maintain PLC and HMI programs.
• Support installation, commissioning, start-up, and validation of new equipment.
• Create electrical schematics, wiring diagrams, and equipment manuals.
• Collaborate with Manufacturing Engineering, Maintenance, Quality, and Production teams on improvements.
• Analyze machine data and recommend reliability improvements.
• Develop preventive maintenance procedures and troubleshooting guides.
• Assist with robotics integration and Industry 4.0 initiatives where applicable.
• Support vendors and technicians during installations and repairs.
• Train maintenance staff on operation and troubleshooting.
• Ensure compliance with safety standards and company policies.
• Participate in root-cause analysis for equipment downtime.

Skills

PLC programming

HMI development

Electrical engineering

Automation engineering

Troubleshooting

Industrial networking

Schematic reading

Project management

Team collaboration

Industry 4.0

Education

Bachelor's degree in Electrical Engineering

Bachelor's degree in Controls Engineering

Bachelor's degree in Mechatronics Engineering

Equivalent experience

Tools

AutoCAD Electrical

Allen-Bradley PLCs

HMI design tools

Job description

Job Description

Job Summary

Feldmeier Equipment is seeking a Controls Engineer to join our Manufacturing Engineering team. This position will play a critical role in supporting, troubleshooting, and improving manufacturing equipment across our facilities. The Controls Engineer will be responsible for reverse engineering legacy equipment, including IMCAR systems, while developing and maintaining controls solutions for new and existing automated equipment. This role combines hands-on troubleshooting with engineering design and continuous improvement initiatives to support production, quality, safety, and operational efficiency.

Essential Duties and Responsibilities

• Reverse engineer existing manufacturing equipment to understand, document, and improve machine functionality.


• Troubleshoot electrical, controls, PLC, HMI, servo, VFD, and automation-related issues on production equipment.


• Design, develop, modify, and maintain PLC and HMI programs.


• Support the installation, startup, commissioning, and validation of new manufacturing equipment.


• Create and maintain electrical schematics, controls documentation, wiring diagrams, and equipment manuals.


• Work with Manufacturing Engineering, Maintenance, Quality, and Production teams to identify and implement process improvements.


• Analyze machine performance data and recommend improvements to increase equipment reliability and efficiency.


• Develop preventive maintenance recommendations and troubleshooting procedures.


• Assist with integrating robotics, automation technologies, and Industry 4.0 initiatives where applicable.


• Support vendors, contractors, and equipment manufacturers during installations, upgrades, and repairs.


• Train maintenance technicians and production personnel on equipment operation and troubleshooting.


• Ensure all equipment controls comply with safety standards and company policies.


• Participate in root cause analysis and corrective action activities for equipment failures and production issues.

Required Qualifications

• Bachelor's degree in Electrical Engineering, Controls Engineering, Mechatronics Engineering, or related field; equivalent experience may be considered.


• Minimum 3 years of experience in industrial controls engineering, automation, or manufacturing engineering.


• Experience programming and troubleshooting PLC systems; Allen-Bradley experience preferred.


• Experience with HMI development and industrial networking.


• Strong understanding of electrical systems, sensors, motors, drives, and control circuits.


• Ability to read and create electrical schematics and technical documentation.


• Strong problem-solving and analytical skills.


• Ability to work independently and manage multiple projects simultaneously.

Preferred Qualifications

• Experience reverse engineering machinery and legacy control systems.


• Experience with servo systems, motion control, and automated manufacturing equipment.


• Familiarity with robotics and automated welding systems.


• Experience using AutoCAD Electrical or similar electrical design software.


• Understanding of manufacturing processes involving stainless steel fabrication, welding, machining, rolling, or forming equipment.


• Knowledge of industrial communication protocols including Ethernet/IP, Modbus, and Profinet.

Physical Requirements

• Ability to work in both office and manufacturing environments.


• Ability to stand, walk, climb ladders, and access manufacturing equipment.


• Ability to occasionally lift up to 50 pounds.


• Ability to work around energized electrical and automated equipment while following all safety procedures.

Key Success Measures

• Reduced equipment downtime.


• Improved machine reliability and production efficiency.


• Successful implementation of automation and controls improvements.


• Complete and accurate controls documentation.


• Effective support of production and maintenance teams.