Controls Engineer

Essex Solutions; Fort Wayne (IN); On-site; USD 90,000 - 120,000; Full time

Job summary

Essex Solutions in Indiana is seeking a Controls Engineer to design, develop, and implement advanced automation and control systems for magnet wire manufacturing. You will bridge electrical, mechanical, and IT disciplines to deliver reliable, scalable solutions.

Responsibilities include PLC programming, schematic design with AutoCAD Electrical, BOM creation, vendor coordination, and hands-on commissioning. The role emphasizes safety, data-driven decisions, and supporting new equipment launches.

Qualifications

• Bachelor’s degree in Electrical Engineering, Electrical Engineering Technology, Mechatronics, Automation Engineering, or equivalent experience.
• Experience in electrical design, controls engineering, drive coordination, and industrial automation.
• Proficiency in electrical schematic design using AutoCAD Electrical or similar tools.
• Advanced problem-solving and analytical skills with a data-driven approach.
• Strong communication and collaboration across functions.

Responsibilities

• Design, develop, and implement automation and control systems for new and existing manufacturing equipment.
• Contribute to control system architecture and establish technical standards across projects (PLC, HMI, SCADA, networking).
• Drive process improvements and equipment innovations to enhance safety, quality, efficiency, and cost performance.
• Execute hands-on technical work including: Electrical system design, PLC programming, and system troubleshooting.
• Support new equipment introduction, including evaluation, installation, commissioning, and production launch.
• Evaluate prototype equipment, analyze performance data, and recommend design improvements.
• Design and review electrical schematics using AutoCAD Electrical.
• Collaborate with mechanical, electrical, and manufacturing teams to ensure effective electro-mechanical system design.
• Develop BOMs, support vendor selection, and assist with procurement activities.
• Create and maintain technical documentation, standards, and best practices.
• Support project planning, including scope definition, scheduling, and risk identification.
• Communicate project status, risks, and milestones to stakeholders.
• Promote and adhere to all safety standards while maintaining an organized work environment.

Skills

Electrical design

Troubleshooting

Communication

Project management

Fast-paced environment

Education

Bachelor’s degree in Electrical Engineering, Electrical Engineering Technology, Mechatronics, Automation Engineering, or equivalent experience

Tools

AutoCAD Electrical

PLC programming

Ignition/SCADA

SQL/Database

SolidWorks

Job description

The Controls Engineer is responsible for the design, development, and implementation of advanced automation and control systems supporting magnet wire manufacturing operations. This role combines strong technical expertise with hands-on execution to deliver reliable, scalable solutions that enhance product quality, operational efficiency, and cost performance.

This individual plays a key role in defining technical strategies, executing complex projects, and collaborating cross-functionally with engineering and operations teams to advance manufacturing capabilities.

Key Responsibilities

• Design, develop, and implement automation and control systems for new and existing manufacturing equipment
• Contribute to control system architecture and establish technical standards across projects (PLC, HMI, SCADA, networking)
• Drive process improvements and equipment innovations to enhance safety, quality, efficiency, and cost performance
• Execute hands-on technical work including:
• Electrical system design and integration
• PLC programming and development of control strategies
• System troubleshooting and root cause analysis
• Support new equipment introduction, including evaluation, installation, commissioning, and production launch
• Evaluate prototype equipment, analyze performance data, and recommend design improvements
• Design and review electrical schematics using tools such as AutoCAD Electrical
• Collaborate with mechanical, electrical, and manufacturing teams to ensure effective electro-mechanical system design
• Develop Bills of Materials (BOMs), support vendor selection, and assist with procurement activities
• Create and maintain technical documentation, standards, and best practices
• Support project planning, including scope definition, scheduling, and risk identification
• Communicate project status, risks, and milestones to stakeholders
• Promote and adhere to all safety standards while maintaining an organized work environment

Required Qualifications

• Bachelor’s degree in Electrical Engineering, Electrical Engineering Technology, Mechatronics, Automation Engineering, or equivalent experience
• Experience in electrical design, controls engineering, drive coordination, and industrial automation
• Strong hands‑on experience with equipment design, system integration, and troubleshooting
• Proficiency in electrical schematic design using AutoCAD Electrical or similar tools
• Advanced problem‑solving and analytical skills with a data‑driven approach
• Experience using diagnostic tools such as oscilloscopes and digital multimeters
• Strong knowledge of electrical codes and safety standards (NEC, NFPA 70E)
• Proven ability to develop technical documentation and standard operating procedures
• Strong communication skills and ability to collaborate across functions
• Ability to manage multiple priorities in a fast‑paced environment
• Willingness to travel up to 40%, including international travel

Preferred Qualifications

• Experience with PLC platforms such as Allen‑Bradley, Siemens, Omron, or Keyence
• Experience with SCADA systems (e.g., Ignition) and SQL/database integration
• Familiarity with IT/OT infrastructure, including:
• Server environments and system administration
• Database management and data architecture
• Industrial networking and network design
• Knowledge of facility electrical systems, including:
• Power distribution and load planning
• Switchgear and switchboard applications
• Electrical load and usage analysis
• Familiarity with mechanical design tools such as SolidWorks
• Experience with structured text programming and higher-level languages (e.g., Python, C++)
• Exposure to additive manufacturing (3D printing)
• Experience in manufacturing or industrial automation environments

Success in This Role

• Delivers high-quality automation solutions that improve equipment reliability and performance
• Becomes a trusted technical resource for complex troubleshooting and system design
• Successfully supports new equipment launches and process improvements
• Builds strong working relationships across engineering, production, and maintenance teams