Controls Engineer

United Employment Group, Inc.; Tomball (TX); On-site; USD 90,000 - 120,000; Full time

Job summary

United Employment Group, Inc. seeks an experienced Controls Engineer for an onsite forging facility role. You will write and troubleshoot PLC programs on Allen-Bradley platforms, develop HMIs, and tune VFDs for press and conveyor systems.

Responsibilities include upgrading control systems, maintaining I/O lists and schematics, and ensuring OSHA‑compliant safety controls. You will collaborate with maintenance and production in a fast, hands‑on environment.

Qualifications

• 3+ years hands-on PLC programming in manufacturing.
• Proficient with Allen-Bradley Rockwell platforms.
• HMI development and understanding of electrical schematics.
• Strong troubleshooting mindset for complex control systems.
• LOTO safety discipline and OSHA awareness.

Responsibilities

• Write, modify, troubleshoot, and document PLC programs for forging lines.
• Develop and modify HMI applications for operators and supervisors.
• Program and tune VFD parameters across presses and conveyors.
• Lead controls projects from scope to installation and commissioning.
• Maintain electrical schematics, I/O lists, and revision history.

Skills

PLC programming

Industrial electrical systems

HMI development

Troubleshooting

Safety standards

LOTO

Education

Associate or Bachelor's degree in Electrical Engineering Technology or related field

Industrial Automation degree/field

Tools

FactoryTalk View

PanelView

RSLogix 5000 / Studio 5000

ControlLogix / CompactLogix

Siemens S7 / TIA Portal

Job description

Our client is looking for an experienced Controls Engineer for an onsite, hands‑on role at their Forging facility.

Overview:

PLC Programming & Control Systems — Primary Responsibility

• Write, modify, troubleshoot, and document PLC programs across the facility — Allen-Bradley/Rockwell platforms (ControlLogix, CompactLogix, MicroLogix) are the primary environment; experience with Siemens S7/TIA Portal is a plus
• Develop and modify HMI applications — FactoryTalk View, PanelView, or equivalent; ensure operator interfaces are clear, functional, and accurate
• Program and maintain VFD (Variable Frequency Drive) parameters and fault response logic across press drives, conveyor systems, and auxiliary equipment
• Support controls modifications for process improvements, press upgrades, and new equipment installations — from specification through commissioning
• Maintain and update controls documentation — electrical schematics, I/O lists, program comments, and revision history — ensuring records accurately reflect the as‑built condition of all systems
• Develop and implement PLC‑based safety logic improvements — press guarding, two‑hand controls, light curtains, E‑stop circuits — in compliance with OSHA and NFPA 79 standards

Forging Press & Production Equipment Controls

• Troubleshoot and repair control systems on mechanical forging presses, hydraulic presses, trim presses, and upsetters — including press clutch/brake control, stroke control, tonnage monitoring, and die protection systems
• Support induction heating system controls — temperature profiling, power regulation, and billet handling integration
• Maintain heat treat furnace controls — temperature controllers, atmosphere monitoring, and process data logging systems
• Troubleshoot and maintain conveyor, transfer, and material handling automation integrated with the forging line
• Respond to production equipment electrical failures during all shifts — this is an active production environment and downtime response is expected

Electrical Systems & Infrastructure

• Troubleshoot AC/DC electrical systems throughout the facility — 480V, 240V, and 24VDC control circuits
• Maintain motor control centers (MCCs), motor starters, contactors, and overloads
• Perform and direct LOTO (Lockout/Tagout) procedures on all electrical equipment in compliance with OSHA 1910.147
• Support preventive maintenance on electrical panels, control enclosures, and field devices — sensors, proximity switches, encoders, and limit switches
• Coordinate with outside controls contractors and OEM service technicians on major equipment overhauls or upgrades
• Identify control system improvement opportunities — cycle time reduction, fault detection, press monitoring, and uptime improvement
• Lead small‑to‑medium controls capital projects from scope definition through installation and commissioning
• Implement predictive maintenance triggers through PLC‑based monitoring — cycle counters, fault frequency tracking, and condition‑based alerts
• Train maintenance technicians on basic PLC fault interpretation and HMI navigation to reduce response time to minor faults

QUALIFICATIONS

Required

• 3+ years of hands‑on PLC programming experience in a manufacturing environment — writing and modifying ladder logic, function block, or structured text programs in production settings
• Allen‑Bradley / Rockwell Automation proficiency — ControlLogix, CompactLogix, or MicroLogix platforms; Studio 5000 / RSLogix 5000 programming environment
• HMI development experience — FactoryTalk View, PanelView, or equivalent touchscreen operator interface platforms
• Solid understanding of industrial electrical systems — 480V three‑phase, motor controls, VFDs, control wiring, and PLC I/O
• Ability to read and interpret electrical schematics, P&IDs, and control wiring diagrams
• Hands‑on troubleshooting mentality — comfortable on the plant floor, in control panels, and working alongside maintenance and production personnel
• LOTO proficiency and demonstrated electrical safety discipline

Preferred

• Forging or heavy press manufacturing experience — familiarity with the controls demands of mechanical and hydraulic forging presses is a significant advantage
• VFD programming and commissioning — Allen‑Bradley PowerFlex, Danfoss, Yaskawa, or similar
• Safety PLC / safety relay experience — GuardLogix, Pilz PNOZ, or Sick safety systems
• Induction heating system experience — Ajax Tocco, Inductotherm, or similar
• SCADA / data historian experience — FactoryTalk Historian, Ignition, or similar
• Associate or Bachelor's degree in Electrical Engineering Technology, Industrial Automation, or a related technical field