Controls Engineer IV -- CRNGJP00028958

Compunnel Inc.; Hickory (NC); On-site; USD 80,000 - 100,000; Full time

Job summary

A leading engineering and manufacturing company is seeking a Controls Engineer IV in Hickory, NC. This senior-level role is tasked with designing, developing, and maintaining advanced control systems for fiber optic cable manufacturing. Candidates should possess a bachelor's degree in engineering and a minimum of 4 years in automation environments. The position entails programming Allen-Bradley PLCs, leading projects, and ensuring compliance with safety standards. The company offers contract employment, requiring onsite work from Monday to Friday.

Qualifications

• 4+ years of manufacturing experience with PLCs, HMIs, and VFDs.
• Experience with Allen-Bradley ControlLogix PLCs.
• Strong understanding of machine control systems.

Responsibilities

• Design and implement new automation and control systems.
• Lead controls engineering scope for process improvements.
• Troubleshoot complex process and control system issues.

Skills

Allen-Bradley ControlLogix PLC programming

HMI/SCADA programming

Electro-mechanical systems

Process troubleshooting

AutoCAD Electrical proficiency

Education

Bachelor’s degree in Electrical Engineering or related field

Tools

AutoCAD Electrical 2023

Job description

Location: 1164 23rd Street SE, Hickory, NC 28601

Work Type: Onsite

Schedule: Monday–Friday | 8:00 AM – 5:00 PM (Overtime as required)

Interview Process: Phone interview followed by onsite interview (virtual option for non-local candidates)

Position Summary

The Controls Engineer IV is responsible for the design, development, implementation, and support of advanced automation and control systems for a fiber optic cable manufacturing facility. This senior-level role leads complex automation projects, mentors junior engineers, interfaces with external system integrators, and ensures robust, safe, and cost-effective process control solutions in alignment with company standards.

Key Responsibilities

• Create, modify, debug, and optimize Allen-Bradley ControlLogix PLC programs (v20 or higher) using ladder logic, structured text, and function block diagrams
• Design and implement new automation and control systems for manufacturing processes
• Lead controls engineering scope for process improvements, capital expansion projects, and obsolescence mitigation initiatives
• Develop robust, scalable, and cost-effective machine control systems

Project Execution

• Participate in all phases of automation projects, including:
• System design and specification
• Fabrication and vendor oversight
• Offline integration and testing
• Installation and commissioning
• Production startup support
• Training of plant personnel
• Technology transfer
• Independently follow equipment construction at vendor facilities
• Interface with and manage external system integrators to deliver fully integrated equipment systems

Electrical Design & Documentation

• Generate and interpret electrical drawings using AutoCAD Electrical 2023, including:
• Prepare initial CAD layouts for complete control systems and sub-sections
• Review electrical drawing packages for compliance with internal engineering standards

Troubleshooting & Support

• Troubleshoot complex process, electrical, and automation issues using sound engineering principles
• Work closely with technicians and maintenance teams to resolve equipment and control system issues
• Support continuous improvement efforts through root cause analysis and corrective actions

Safety & Compliance

• Ensure proactive safety measures are incorporated into all equipment and processes
• Identify and correct potential safety or environmental issues using NEC, NFPA, and other applicable codes
• Enforce safety procedures including Lock-Out/Tag-Out (LOTO)
• Comply with all PPE requirements
• Mentor and train junior controls engineers
• Execute project assignments independently or in a team-based environment with minimal supervision
• Carry assignments through to completion with a high level of accountability

Required Qualifications

Education

• Bachelor’s degree (BS) in Electrical Engineering, Computer Engineering, Mechanical Engineering, or related field
• Other engineering degrees may be considered with relevant experience; BS degree required

Experience

• 4+ years of manufacturing experience working with PLCs, HMIs, and VFDs in automation environments
• Preferred: 8+ years of relevant controls engineering experience

Technical Skills

• Hands-on experience programming Allen-Bradley ControlLogix PLCs (v20+)
• HMI/SCADA programming experience in a plant environment
• Strong understanding of:
  
  • Machine and motion control systems
  • Electro-mechanical systems
  • VFD and servo programming
  • Ability to independently troubleshoot and resolve complex process and controls issues
  • Proficiency with AutoCAD Electrical for control system design

Desired / Preferred Skills

• Experience with extrusion and cable winding processes
• Knowledge of legacy control systems, networks, and software
• Experience with OSI PI (historian) interfaces
• Experience with iFIX 5.9 or higher
• Beckhoff PLC experience
• Entrepreneurial mindset with the ability to design innovative control solutions
• Visionary thinking with strong system-level perspective
• Excellent written, verbal, and interpersonal communication skills

PPE Requirements

• Safety shoes
• Safety glasses
• Ear protection (as required)
• High-visibility vest

Seniority level

Mid-Senior level

Employment type

Contract

Job function

Production, Manufacturing, and Engineering

Industries

Artificial Rubber and Synthetic Fiber Manufacturing, Engineering Services, and Industrial Machinery Manufacturing