Lead Controls Engineer, Industrial Automation

Vulcan Elements; Benson (NC); On-site; USD 130,000 - 190,000; Full time

Job summary

Vulcan Elements in the United States is seeking a Senior Controls Engineer to lead controls and software integration for a massive facility expansion. You will provide technical leadership for a team of controls engineers and own the hardware/software interface of production equipment.

This role requires deep expertise in industrial automation, hands-on PLC/HMI development, and the ability to establish site-wide automation standards. Occasional travel to OEM facilities is expected.

Qualifications

• Bachelor’s or Master’s degree in electrical engineering, automation engineering, mechatronics, or related field.
• 8+ years of direct industrial automation and controls experience.
• Hands-on with Siemens and Allen-Bradley/Rockwell PLCs and HMIs.
• ISA-88 batch control: physical and procedural models, phase logic design, equipment/recipe separation.
• Deep understanding of servos, VFDs, conveyors, robotic cells, and automated material handling systems.

Responsibilities

• Lead hands-on programming, debugging, and commissioning of Siemens and Allen Bradley/Rockwell PLCs and HMIs for new and existing automation equipment.
• Develop, modify, and maintain PLC code structures, HMI screens, safety circuits, device mapping, and networking configurations.
• Own and evolve the site controls standard: code architecture, state machines, alarm and HMI conventions.
• Own the ISA-88 physical and procedural models; execute batch-engine placement study and implementation.
• Define safety PLC and functional safety conventions with EHS and equipment vendors.
• Support integration and commissioning of robotics, vision systems, AGVs, conveyors, and motion control systems.
• Configure and maintain communications between PLCs/HMIs and higher-level systems (SCADA); own the controller-side data interface.
• Review vendor electrical schematics, controls architectures, and PLC/HMI logic; support FATs and SATs.
• Serve as a senior escalation point for diagnosing complex automation issues.
• Analyze OEE, downtime data, and SCADA/MES insights to identify automation improvements.

Skills

Siemens PLC programming

Allen-Bradley PLC

HMI development

Industrial automation

SCADA/MES integration

Electronic networking

Education

Bachelor's or Master’s in Electrical/Automation/Mechatronics

Tools

Siemens PLC

Allen-Bradley/Rockwell PLC

HMI platforms

SCADA systems (Ignition, FactoryTalk, Wonderware)

ISA-88 batch control

Industrial communication protocols (Ethernet/IP, Profinet, EtherCAT, OPC UA, Modbus)

Job description

Vulcan Elements in the United States is seeking a Senior Controls Engineer to lead controls and software integration for a massive facility expansion. You will provide technical leadership for a team of controls engineers and own the hardware/software interface of production equipment.

This role requires deep expertise in industrial automation, hands-on PLC/HMI development, and the ability to establish site-wide automation standards. Occasional travel to OEM facilities is expected.