Controls Engineer

Vangrace; Danville (VA); On-site; USD 65,000 - 85,000; Full time

Job summary

Vangrace in Danville, Virginia, is looking for a skilled Controls Engineer to oversee the maintenance and troubleshooting of critical manufacturing systems. You will be responsible for implementing plans to improve equipment performance and reliability while supporting the manufacturing process.

The ideal candidate possesses a BS in Electrical Engineering, along with hands-on experience in instrumentation and PLC programming. Strong skills in AutoCAD and networking are also essential. Competitive compensation and opportunities for professional growth are offered.

Qualifications

• Proficiency in AutoCAD and MS Office.
• Experience with instrumentation and maintenance in industrial automation.
• Understanding of lean techniques and quality systems.

Responsibilities

• Maintain critical equipment and improve reliability.
• Propose continuous improvement plans for CI.
• Assist with preventive maintenance procedures.

Skills

Electrical Controls

Instrumentation

PLC programming

AutoCAD

MS Office

Networking skills

Lean techniques

Education

BS Degree in Electrical or Electronic Engineering

Tools

WinCC

Wonderware

Siemens PLCs

Job description

The Controls Engineer responsibilities include all equipment, parts, manufacturing and maintenance processes of the plant site. Support all (measures, tracks, and reports) the manufacturing processes critical equipment performance indicators such as Uptime, MTBF, and PMs (specifically related to Electrical, Automation, Siemens Controllers, and Instrumentations).

The Controls Engineer assists and advises manufacturing in troubleshooting and resolving manufacturing problems where Electrical Controls are “mission critical” (i.e. E‑Beam / LFE systems, Tension Control systems, Winder/Rewinder, Mixing/weighing systems, etc.).

Responsibilities

• Elaborate plans for maintaining the manufacturing process critical equipment up to date with the latest available technologies from the manufacturer and/or competitive sources.
• Elaborate and propose plans for CI continuous Improvement of the manufacturing process critical equipment with specific aim at improving Uptime, MTBF, and overall reliability.
• Elaborate and propose plans for annual CAPEX projects.
• Assist and coach manufacturing and maintenance supervisors and technicians with prioritizing maintenance daily work schedule and PMs/TPM activities and troubleshooting.
• Assist and coach the spare parts management system coordinator.
• Write and document preventive maintenance procedures, calibration procedures, and trainings especially during commissioning of new or upgraded equipment.
• Liaison between IT and plant for manufacturing network issues and troubleshooting.
• Flexible work schedule includes some weekend activity and on‑call support for off‑hours protocol.

Requirements

• BS Degree Electrical or Electronic Engineering, proficiency in AutoCAD and MS Office.
• Experience with instrumentation and maintenance in industrial automation in a high‑volume fast‑paced environment, working/troubleshooting with production and maintenance personnel.
• Experience with lean techniques and structured quality systems.
• Working knowledge of Siemens PLC programs installing, troubleshooting, programming and tuning AC/DC/VFD motor drives, single/multi loops Siemens controllers and PLCs.
• Use ladder logic and P&ID diagrams for automation, including extruder motors, melt and liquid pumps, load cells, temperature pressure level controllers, tension winding/unwinding controllers.
• Experience in extrusion or injection molding production and/or web handling/transport, linear tension control systems, load cells, general instrumentation calibrations environment.
• Experience reading/editing and understanding documents associated with electrical, instrumentation and automation systems (including process loop drawings, P&IDs, schematics, wiring diagrams, installation details, logic diagrams, mechanical prints and specification sheets).
• HMI software programming skills: WinCC, Wonderware or similar data historians and loggers.
• PLC programming skills: SIEMENS (required), Automation DIRECT, AB, Mitsubishi PLCs (plus).
• Networking skills with industrial networks (ProfiNet, Ethernet/IP, DeviceNet, TCP/IP protocol).
• Write inventive maintenance procedures, calibration procedures.
• Identify, source, and control stock for key spare parts.
• Ability to be on call for emergencies.