Controls Software & Standards Lead

Henshaw, Inc; Armada (MI); On-site; USD 120,000 - 170,000; Full time

Job summary

Henshaw, Inc. in Michigan seeks a Controls Software & Standards Lead Programmer to spearhead PLC/HMI development and establish coding standards for automation projects. This role blends hands-on programming with leadership to improve tools and practices.

The ideal candidate will focus on PowerFlex VFDs and Allen-Bradley controls, delivering reliable software architectures, mentoring staff, and coordinating with multi-disciplinary teams to ensure project success.

Qualifications

• Significant hands-on experience programming and commissioning industrial automation systems.
• Proficiency with Allen-Bradley ControlLogix and CompactLogix PLCs.
• Experience commissioning and troubleshooting PowerFlex VFDs.
• Experience developing reusable PLC code, templates and standards.
• Strong documentation, communication, and problem-solving skills.

Responsibilities

• Lead PLC and HMI software development from design through commissioning.
• Develop modular, reusable code for sequencing, control, diagnostics, and fault recovery.
• Review designs for quality and compliance with Henshaw standards.
• Mentor programmers on architecture, troubleshooting, and commissioning.
• Coordinate with electrical/mechanical/project teams to resolve issues.
• Configure, commission, and troubleshoot PowerFlex VFDs and drive parameters.

Skills

PLC programming

PowerFlex VFDs

Studio 5000 Logix Designer

Code reviews

Mentoring

Electrical schematics

Networking EtherNet/IP

Documentation

Tools

Studio 5000

PowerFlex VFDs

EtherNet/IP

Job description

Henshaw is seeking a Controls Software & Standards Lead Programmer to lead controls software development, strengthen programming standards, and improve the engineering tools used to deliver automation projects. This role combines technical leadership with hands-on programming, troubleshooting, and commissioning, with a strong emphasis on Allen-Bradley PowerFlex variable frequency drives. The ideal candidate builds reliable, maintainable software and helps the entire engineering team work more consistently and efficiently.

Key Responsibilities

PLC Software and Technical Leadership

• Lead PLC and HMI software development from initial design through commissioning and customer acceptance.
• Develop clear, modular, reusable code for machine sequencing, equipment control, diagnostics, and fault recovery.
• Review software designs and code for quality, consistency, and compliance with Henshaw standards.
• Mentor programmers and provide practical guidance on architecture, troubleshooting, and commissioning.
• Coordinate with electrical, mechanical, and project teams to resolve technical issues and meet project requirements.

Programming Standards

• Develop, maintain, and enforce PLC and HMI programming standards, including naming conventions, program structure, equipment interfaces, alarms, and documentation.
• Build and maintain reusable code libraries, Add-On Instructions, User-Defined Data Types, and project templates.
• Establish consistent practices for software version control, backups, change tracking, and release management.
• Incorporate lessons learned from commissioning and field support into standards and reusable software.
• Develop and improve tools that reduce repetitive engineering work and improve accuracy.
• Create utilities for code generation, tag management, configuration, documentation, and software validation.
• Evaluate existing workflows, identify opportunities for improvement, and help the team adopt effective tools and practices.
• Maintain clear documentation so tools and libraries can be used and supported across the engineering team.
• Configure, commission, and troubleshoot Allen-Bradley PowerFlex VFDs, including PowerFlex 525 and 755 families.
• Verify drive setup against motor nameplate data, application requirements, and approved electrical designs.
• Configure EtherNet/IP communications, command and status interfaces, reference signals, and drive diagnostics.
• Perform motor tuning and adjust acceleration, deceleration, speed limits, and other application parameters.
• Integrate drive permissives, interlocks, fault handling, and recovery sequences into PLC software.
• Verify applicable drive safety functions with the responsible engineering team and document commissioning results.
• Maintain parameter backups and accurate final drive configurations.

Required Qualifications

• Significant hands-on experience programming and commissioning industrial automation systems.
• Strong proficiency with Allen-Bradley ControlLogix and CompactLogix PLCs and Studio 5000 Logix Designer.
• Demonstrated experience commissioning and troubleshooting PowerFlex VFDs.
• Experience developing and maintaining reusable PLC code, programming standards, and engineering templates.
• Strong understanding of industrial Ethernet networks, EtherNet/IP devices, and network troubleshooting.
• Ability to read electrical schematics and troubleshoot interactions among software, wiring, motors, drives, and field devices.
• Experience leading technical work, reviewing code, and mentoring other programmers.
• Strong documentation, communication, and problem-solving skills.

Compensation and benefits: Negotiable based on experience - Senior Position