Lead Controls Engineer

100KCrossing; Holcomb (KS); On-site; USD 110,000 - 140,000; Full time

Job summary

100KCrossing seeks a Lead Controls Engineer to provide technical direction for technology-based processes, industrial automation, and plant control environments in Holcomb, KS. You will drive uptime, enforce IT/OT standards, and lead modernization initiatives across both modern and legacy equipment.

The role requires strong PLC programming skills, experience with Schneider Electric/Modicon platforms, and hands-on work with Ignition/iFix SCADA/HMI systems in a live manufacturing setting.

Qualifications

• Bachelor's degree or equivalent in engineering or technical discipline.
• 6+ years in information systems or industrial automation fields with programming experience.
• Strong PLC programming, ladder logic, structured text, I/O mapping, and electrical schematic interpretation.

Responsibilities

• Provide technical leadership for technology-based processes and plant automation environments.
• Develop and manage technical environments to fulfill SLA and support operations.
• Program, commission, and troubleshoot PLC-based control systems (Schneider/Modicon).
• Diagnose and resolve complex failures across controls, electrical circuits and networks.
• Support and troubleshoot material-handling systems, conveyors, drives, sensors and interlocks.
• Maintain and troubleshoot Ignition and iFix SCADA/HMI platforms.

Skills

PLC programming

Ladder logic

Structured text

I/O mapping

SCADA systems

HMI development

Industrial networks

Education

Bachelor's degree in Engineering or related field

Tools

Schneider Electric / Modicon

Ignition

GE iFix

Keyence

Cognex

SICK Vision

Industrial networks

Job description

We are looking for a Lead Controls Engineer to provides technical direction and oversight for technology-based processes, industrial automation, and plant control environments in Holcomb, KS. They will develop and manage technical architectures to meet organizational IT service level agreements, plans technology solutions to enhance mission-critical business operations, and enforces IT/OT standards. They will drive continuous operational uptime, conducts root-cause diagnostics across PLC, HMI, and industrial network layers, and oversees controls modernization initiatives across both modern and legacy equipment. Type: Full-Time (Exempt)

Key Responsibilities

• Provide technical leadership and operational direction for technology-based processes, system developments, and plant automation environments.
• Develop and manage technical environments across departments to fulfill organizational service level agreements and support mission-critical operations.
• Program, commission, and troubleshoot PLC-based control systems using ladder logic, structured text, and I/O mapping, with emphasis on Schneider Electric / Modicon platforms.
• Trace and resolve complex operational failures across controls, electrical circuits, communications, and mechanical equipment in a live manufacturing environment.
• Support and troubleshoot automated material-handling systems, including conveyors, motors, drives, sensors, photo eyes, interlocks, and sequencing logic.
• Diagnose and maintain integrated SCADA and HMI platforms (specifically Ignition and iFix) across connected plant-floor equipment.
• Integrate, maintain, and troubleshoot industrial barcode scanning and vision equipment (Keyence, Cognex, and SICK).
• Troubleshoot industrial communication protocols between PLCs, field devices, HMIs, scanners, and enterprise IT systems.
• Support legacy control systems while evaluating, planning, and executing controls upgrades, component replacements, and automation modernization projects.
• Define, implement, and maintain IT policies, coding standards, System Development Lifecycle (SDLC) methodologies, and operational procedures.
• Direct technical vendors, evaluate information systems proposals, negotiate for products/services, and advise on hardware and software purchases.
• Develop and execute integrated test plans, evaluate alternative technical implementations, and collaborate with cross-functional teams and non-technical stakeholders.

Required Skills & Experience

• Bachelor's degree in Computer Science, Information Systems, Engineering, or a technical discipline (equivalent work experience accepted).
• 6+ years of experience in Information Systems, Controls Engineering, or related industrial automation fields with proven programming experience.
• Advanced knowledge in programming, commissioning, and troubleshooting PLC-based systems, ladder logic, structured programming, I/O mapping, and electrical schematic interpretation.
• Strong working knowledge across multiple technologies, including SCADA, 4GL programming, scripting languages, server-based systems, and SQL.
• Advanced experience with System Development Lifecycle (SDLC) methodologies, code reviews, technical specification development, and integrated test execution.
• Excellent verbal and written communication skills with demonstrated ability to explain complex technical concepts to non-technical audiences and apply basic project management practices.

Preferred Qualifications

• Extensive hands-on experience with Schneider Electric/Modicon PLC hardware and programming software.
• Applied experience with Ignition and GE iFix SCADA/HMI platforms.
• Direct experience integrating and troubleshooting Keyence, Cognex, and SICK industrial vision/scanning systems.