Controls Engineer

Frey Consulting Group; Illinois; On-site; USD 90,000 - 140,000; Full time

Job summary

Frey Consulting Group seeks an experienced engineer to design and implement industrial control systems for automated manufacturing projects. You will apply PLC programming and robotics integration expertise to deliver robust solutions across client facilities.

Reporting to the Head of Engineering, you will collaborate with cross-functional teams, conduct testing, provide training, and support transitions to Industry 4.0 in a dynamic environment. Travel may be required for on-site work.

Qualifications

• Bachelor’s Degree in Electrical Engineering, Control Engineering, or related field.
• Minimum 3 years experience in designing and implementing industrial control systems.
• Proficiency in PLC programming and robotics integration.
• Strong problem-solving and ability to manage multiple projects.
• Excellent communication for client engagement.

Responsibilities

• Design and implement automated control systems to reduce downtime.
• Collaborate with multidisciplinary teams to integrate robotics solutions across facilities.
• Develop preventive maintenance plans for equipment lifecycle.
• Analyze and troubleshoot system failures with high first-visit resolution.
• Conduct onsite training workshops for personnel.
• Spearhead Industry 4.0 upgrades for major clients by year-end.

Skills

PLC programming

Robotics integration

Problem-solving

Communication skills

Project management

Education

Bachelor’s Degree in Electrical Engineering, Control Engineering, or related field

Job description

We have 7 Inbound and 6 Outbound robotics cells that will be installed in this facility.For inbound, we have a Fanuc robot interacting with an Autostore via Exacta software via the PLC interface, 2 Keyence vision systems per cell, and 3 barcode scanners per cell (2 fixed-mounted and 1 on the robot arm tooling). AGV interfacing through sister business units, PLC, an Ignition HMI, and an Allen Bradly PLC (V.33).

For Outbound we have a Fanuc robot interacting with an Autostore via Exacta software through the PLC, 1 vision system per cell and 2 Panther labelers. Same AGV interface as above. Ignition HMI and Allen Bradley PLC.

The programs have already been written but only loaded into one of each cell; PLCs will most likely need firmware flashed up to the correct version, and all IPs and settings will need to be done on the 9 cells not set up in our shop for testing. IO check will need to be done and then working through any real world testing with all of the other parties involved. The labelers will need to be commissioned as well. Once the cells are commissioned we will be helping train the operators and just providing production support and troubleshooting issues as the arise.

Project Location :

SOP / Duration:

August 17 – September 4, 2026

3 Weeks

• 60+ hours/week

Travel Information:

Travel expenses, plus daily hotel and food per diem.

Performance Objectives

• Design and implement automated control systems that optimize manufacturing processes, reducing downtime by 20% within the first year.
• Collaborate with multidisciplinary teams to customize and integrate robotics solutions across 10+ client facilities by quarter-end.
• Develop and execute preventive maintenance plans that extend the lifecycle of critical equipment by 15%.
• Analyze and troubleshoot system failures to identify root causes, achieving a resolution rate of 95% on the first visit.
• Conduct training workshops for onsite personnel, ensuring a 25% improvement in workplace safety standards.
• Spearhead the transition to Industry 4.0 solutions, successfully upgrading legacy systems for 5 major clients by year-end.

You will report directly to the Head of Engineering and collaborate closely with a dynamic team of industry experts. Equipped with state-of-the-art design software and access to a comprehensive client network, you’ll have ample resources to innovate and excel. Budget allocation is ample to support continuous technological advancements.

Essential Qualifications

• Bachelor’s Degree in Electrical Engineering, Control Engineering, or a related field.
• Minimum 3 years of proven experience in designing and implementing industrial control systems.
• Proficiency in PLC programming and robotics integration.
• Strong problem-solving skills with the ability to manage multiple projects simultaneously.
• Excellent communication skills for effective collaboration and client engagement.

Role Selling Points

• Be part of an early-stage, innovative company that's shaping the future of engineering talent pipelines.
• Work in a role that offers significant autonomy and the opportunity to directly impact client success and satisfaction.
• Leverage your expertise in a flexible, dynamic environment that values creativity and initiative.