Lead Controls Engineer

Compunnel, Inc.; Springdale, Northern (AR, KY); Hybrid; USD 90,000 - 130,000; Full time

Benefits offered by this job

Job summary

Compunnel, Inc. is seeking a Lead Controls Engineer to provide expert direction and hands-on support for industrial controls in a manufacturing plant.

You will focus on PLC programming, troubleshooting, SCADA/HMI, and plant automation while collaborating with cross-functional teams and vendors. The role involves integrating legacy and modern systems, supporting material-handling equipment, and ensuring reliability and cost-effectiveness.

Qualifications

• Bachelor's degree in a technical field or equivalent experience.
• 6+ years in information systems, controls engineering, or automation.
• Proven PLC programming, commissioning, and troubleshooting experience.
• Experience with Schneider Electric/Modicon PLC platforms.
• Ladder logic and structured programming experience.
• I/O mapping, HMI integration, and interpreting electrical schematics.
• Strong experience with SCADA/HMI systems.
• Industrial networking and communications expertise.
• Scripting and SQL knowledge.
• Root cause analysis across controls, electrical, and equipment systems.

Responsibilities

• Provide technical direction for controls and technology solutions.
• Develop and support environments and solutions for manufacturing operations.
• Program, commission, troubleshoot PLC-based control systems.
• Work with Schneider Electric/Modicon platforms, modern and legacy.
• Troubleshoot production and material-handling equipment.
• Support conveyors, motors, drives, sensors, interlocks, sequencing.
• Perform I/O mapping, HMI integration, and fault diagnosis.
• Troubleshoot SCADA/HMI systems including Ignition and iFix.
• Diagnose issues across PLC, HMI/SCADA, and industrial networks.
• Integrate barcode, scanning, vision systems (Keyence, Cognex, SICK).
• Troubleshoot communications among plant-floor systems.
• Support upgrades and modernization initiatives.
• Perform root-cause analysis and develop specs and test plans.
• Communicate with stakeholders; work in cross-functional teams.

Job description

Job Summary

The Lead Controls Engineer will provide expert technical direction and hands-on support for industrial controls and technology-based processes within a manufacturing plant environment. The role will focus on PLC programming and troubleshooting, SCADA/HMI systems, industrial networking, plant automation, material-handling equipment, and controls modernization. The engineer will work closely with cross-functional teams, technical personnel, vendors, and business stakeholders to identify, develop, implement, and support reliable and cost-effective controls solutions while maintaining applicable standards and methodologies.

Key Responsibilities

• Provide technical direction and recommendations to team members and management for controls and technology solutions


• Develop, maintain, and support technical environments and solutions that enhance mission-critical manufacturing operations


• Program, commission, troubleshoot, and maintain PLC-based control systems in industrial environments


• Work with Schneider Electric/Modicon PLC platforms and support both modern and legacy control systems


• Troubleshoot automated production and material-handling equipment in a live manufacturing environment


• Support conveyors, motors, drives, sensors, photo eyes, interlocks, sequencing, and related material-handling equipment


• Perform I/O mapping, HMI integration, and interpretation of electrical schematics to diagnose faults and restore equipment uptime


• Troubleshoot and support SCADA/HMI systems, including Ignition and iFix


• Diagnose issues across PLC, HMI/SCADA, connected equipment, electrical systems, and industrial communications


• Integrate and troubleshoot industrial barcode, scanning, and vision systems, including Keyence, Cognex, and SICK platforms


• Troubleshoot communications between PLCs, scanners, field devices, HMIs, and other plant-floor systems


• Support controls upgrades, equipment replacements, modernization initiatives, and integration of legacy systems


• Perform root cause analysis across controls, electrical, communications, and equipment systems


• Develop, review, and modify technical specifications, configurations, programs, and coding standards


• Develop and execute integrated test plans to validate controls and technology solutions


• Recommend and develop implementation plans for systems development and operations


• Support technology evaluations, equipment and software recommendations, and related implementation activities


• Work with vendors and technical personnel to support controls and technology solutions


• Maintain awareness of relevant technology developments and trends to support future planning


• Ensure compliance with applicable technology standards, methodologies, procedures, and best practices


• Communicate technical information and recommendations effectively to technical and non-technical stakeholders

Required Qualifications

• Bachelor's degree in Computer Science, Information Systems, Engineering, or another technical field, or equivalent work experience


• 6+ years of experience in Information Systems, controls engineering, industrial automation, or a related technical field


• Proven programming and controls engineering experience


• Strong hands-on experience with PLC programming, commissioning, and troubleshooting in industrial environments


• Experience with Schneider Electric/Modicon PLC platforms


• Experience with ladder logic and structured programming


• Experience with I/O mapping, HMI integration, and interpreting electrical schematics


• Strong manufacturing or plant-floor experience supporting automated production environments


• Strong experience with SCADA/HMI systems


• Experience troubleshooting industrial networking and communications


• Strong knowledge of scripting, server-based technologies, SQL, and related systems


• Experience troubleshooting automated production and material-handling equipment


• Strong diagnostic and root cause analysis skills across controls, electrical, communications, and equipment systems


• Strong understanding of system development lifecycle methodologies


• Experience developing, reviewing, and modifying technical specifications, configurations, and programs


• Experience developing and executing integrated test plans


• Strong verbal and written communication skills, including the ability to communicate technical information to non-technical stakeholders


• Ability to work effectively in a cross-functional team environment and manage multiple priorities

Preferred Qualifications

• Experience with Keyence, Cognex, or SICK barcode, scanning, and vision systems


• Experience with Ignition and iFix SCADA/HMI platforms


• Experience supporting conveyors, motors, drives, sensors, photo eyes, interlocks, and sequencing systems


• Experience working with both legacy and modern industrial control systems


• Experience supporting controls upgrades, replacements, and modernization initiatives


• Basic project management experience