Lead Industrial Controls Engineer

Vulcan-Elements; Benson (NC); On-site; USD 110,000 - 150,000; Full time

Job summary

Vulcan Elements is seeking a Senior Controls Engineer to lead the controls and software integration for a large manufacturing expansion. You will own the hardware/software interface of production and material handling equipment and establish site-wide automation standards.

This high-ownership role requires deep technical expertise in industrial automation, hands-on PLC/HMI programming, and collaboration with OEM vendors; travel up to 20% for test campaigns.

Qualifications

• Bachelor’s or Master’s degree in electrical engineering or related field with 8+ years of automation experience.
• Hands-on experience programming and commissioning Siemens and Allen Bradley PLCs and HMIs.
• Authorship of controls standards, specifications, or code libraries used by others.
• Deep understanding of servos, VFDs, conveyors, robotic cells, and automated material handling.
• Safety PLC programming competence and ISO 13849 / IEC 62061 interlock design knowledge.
• Proficiency with Ethernet/IP, Profinet, EtherCAT, OPC UA, Modbus, and serial communications.

Responsibilities

• Lead hands-on programming, debugging, and commissioning of PLCs and HMIs for new and existing equipment.
• Develop, modify, and maintain PLC code structures, HMI screens, safety circuits, and device mapping.
• Own site controls standards, templates, and code libraries for consistent execution.
• Define ISA-88 models and batch control decisions and implementations.
• Establish safety conventions and collaborate with EHS and vendors.
• Support integration of robotics, vision systems, AGVs, conveyors, and motion control.
• Configure communications between PLCs/HMIs and SCADA/Higher level systems.
• Review vendor schematics and conduct code reviews; support FATs and SATs.
• Serve as senior escalation point for complex automation issues.

Skills

Industrial automation

Controls engineering leadership

SCADA systems

PLC programming

HMI programming

Safety systems

Networking protocols

Education

Bachelor’s or Master’s degree in electrical engineering, Automation Engineering, Mechatronics, or related field

Tools

Siemens PLCs

Allen-Bradley PLCs

HMI programming tools

Ignition

FactoryTalk

Wonderware

Cognex

Keyence

Python

C++

Job description

Vulcan Elements is seeking a Senior Controls Engineer to lead the controls and software integration for a large manufacturing expansion. You will own the hardware/software interface of production and material handling equipment and establish site-wide automation standards.

This high-ownership role requires deep technical expertise in industrial automation, hands-on PLC/HMI programming, and collaboration with OEM vendors; travel up to 20% for test campaigns.