Industrial Controls Technician

Sterling Engineering; Buffalo Grove (IL); On-site; USD 69,000 - 80,000; Full time

Benefits offered by this job

Medical insurance

Dental insurance

Vision insurance

401(k) with company matching

Paid vacation and sick time

Life insurance

Job summary

Sterling Engineering in Buffalo Grove, IL seeks an experienced Industrial Controls Technician to support a highly automated manufacturing operation. The role emphasizes PLC troubleshooting, Cognex vision, HMI interfaces, and broader industrial automation in a fast-paced setting.

The ideal candidate will diagnose and resolve complex controls issues, interpret electrical schematics, and provide hands-on support during night shifts.

Qualifications

• 6+ years of industrial controls, automation, or related troubleshooting experience preferred.
• Experience diagnosing PLC faults, ladder logic, and control-system issues.
• Experience with Cognex vision systems or similar machine-vision tech.

Responsibilities

• Perform advanced troubleshooting, diagnostics, and repair of PLC-controlled equipment to minimize downtime.
• Troubleshoot PLC logic, I/O, comms, and control-system issues.
• Diagnose HMI interfaces, RFID devices, and industrial communications.
• Troubleshoot Cognex vision systems, cameras, sensors, and software.
• Maintain servo drives, VFDs, and motion-control systems.
• Support PLC/HMI software modifications and upgrades.
• Read electrical schematics and PLC logic; document actions.
• Collaborate with engineering/maintenance/production to root-cause failures.

Skills

PLC troubleshooting

Troubleshooting under pressure

Electrical schematics interpretation

Analytical mindset

Off-shift work

Education

Associate degree or equivalent

Tools

Allen-Bradley RSLogix/Studio 5000

FactoryTalk

Siemens S7

Cognex vision systems

Ignition / HMI/SCADA

VFDs / Servo drives

Job description

Sterling Engineering is seeking an experienced Industrial Controls Technician to support a highly automated manufacturing operation in Buffalo Grove, IL.

This position is ideal for a technically strong, hands-on controls professional who enjoys troubleshooting complex automated manufacturing equipment and resolving PLC, HMI, and industrial control system issues.

While titled Industrial Controls Technician, this role requires a level of technical expertise comparable to a junior Controls Engineer. The successful candidate will have extensive experience diagnosing and resolving controls-related problems in a manufacturing environment, with particular emphasis on PLC troubleshooting, Cognex vision systems, HMI interfaces, and industrial automation.

Key Responsibilities

• Perform advanced troubleshooting, diagnostics, and repair of PLC-controlled automated manufacturing equipment to minimize production downtime.
• Troubleshoot PLC logic, I/O, communication faults, and control system issues to identify and resolve equipment failures.
• Diagnose and troubleshoot HMI systems, operator interfaces, RFID systems, and related industrial communication devices.
• Troubleshoot, maintain, and support Cognex vision inspection systems, including cameras, sensors, and associated software.
• Perform troubleshooting and maintenance of servo motors, servo drives, variable frequency drives (VFDs), and motion control systems.
• Support PLC and HMI software modifications, upgrades, and functional verification activities.
• Diagnose industrial networking and communication issues between PLCs, HMIs, sensors, drives, and automated equipment.
• Read and interpret electrical schematics, wiring diagrams, PLC programs, and technical documentation.
• Partner with engineering, maintenance, and production teams to identify root causes of recurring equipment failures and implement corrective actions.
• Provide hands-on technical support for complex automated production lines during night shift operations.
• Assist with equipment upgrades, automation improvements, and qualification activities.
• Document troubleshooting activities, repairs, and system modifications in accordance with manufacturing and quality requirements.
• Provide technical guidance and support to maintenance and automation technicians when resolving complex controls issues.
• Maintain compliance with established safety procedures, including electrical safety and equipment troubleshooting protocols.

Required Qualifications

• Strong hands-on experience troubleshooting PLC-controlled equipment in an industrial manufacturing environment.
• Approximately 6+ years of industrial controls, automation, or related technical troubleshooting experience preferred.
• Demonstrated ability to diagnose PLC faults, troubleshoot ladder logic, and resolve controls-related production issues.
• Experience troubleshooting HMI systems, operator interfaces, and industrial communication devices.
• Experience working with Cognex vision systems or similar industrial machine vision technologies.
• Working knowledge of servo drives, VFDs, motion control, sensors, and industrial automation equipment.
• Ability to interpret electrical schematics, wiring diagrams, and PLC logic.
• Experience supporting high-volume or highly automated manufacturing operations.
• Strong analytical troubleshooting skills and the ability to work independently during off-shift production.
• Associate degree, military technical training, or vocational training in Industrial Controls, Automation, Electrical Technology, or a related discipline preferred.

Preferred Qualifications

• Experience with Allen-Bradley/Rockwell PLC platforms, including RSLogix, Studio 5000/Logix Designer, and FactoryTalk.
• Experience with Siemens S7 PLC systems.
• Experience with Cognex In-Sight vision systems and associated software.
• Familiarity with Ignition or similar industrial HMI/SCADA platforms.
• Experience troubleshooting RFID devices, industrial networks, and automated inspection equipment.
• Background in medical device manufacturing, regulated manufacturing, or other high-volume automated production environments.
• Experience performing PLC/HMI software modifications and supporting automation upgrades.
• Experience supporting equipment qualification, root cause analysis, and continuous improvement initiatives.
• Competitive hourly compensation up to the low $50s/hr, depending on experience.
• Additional night shift differential.
• Direct-hire employment.
• Medical, dental, and vision insurance.
• 401(k) with company matching.
• Paid vacation and sick time.
• Life insurance and short-term/long-term disability coverage.