Lexington Controls & Automation Engineer

Prysmian Group; Lexington (VA); On-site; USD 90,000 - 120,000; Full time

Job summary

Prysmian Group is seeking an experienced Automation & Controls Engineer in the United States (Virginia). You will develop and troubleshoot PLC programs, support HMI/SCADA, and lead capital projects from concept to startup.

The role emphasizes data-driven improvements, diagnostics, and the establishment of robust controls standards across the manufacturing network. Ideal candidates bring 3–7+ years in manufacturing controls, a bachelor’s degree in Electrical Engineering, and experience with

Qualifications

• Bachelor's degree in electrical or related engineering field required.
• 3-7+ years of manufacturing controls and automation experience.
• Experience supporting high-speed manufacturing processes preferred.
• Experience leading automation or capital projects preferred.

Responsibilities

• Develop, maintain, and troubleshoot PLC programs and control systems.
• Support and improve HMI and SCADA applications.
• Diagnose and resolve electrical, instrumentation, and controls-related issues.
• Develop and enforce controls standards across manufacturing equipment.
• Lead controls-related capital projects from concept through implementation.
• Develop manufacturing dashboards and reporting tools.
• Support SPC initiatives and process monitoring systems.

Skills

Automation

Controls engineering

Data-driven

Education

Bachelor's Degree in Electrical Engineering

Tools

PLC programming

HMI/SCADA

Job description

Key Responsibilities

• Automation & Controls
  • Develop, maintain, and troubleshoot PLC programs and control systems.
  • Support and improve HMI and SCADA applications.
  • Diagnose and resolve electrical, instrumentation, and controls-related issues.
  • Maintain control system documentation, backups, and change management records.
  • Develop and enforce controls standards across manufacturing equipment.
  • Support machine startups, commissioning, and process validation activities.
  • Maintain alarm management and machine fault diagnostics.
• Manufacturing Support
  • Provide advanced controls support for production escalations.
  • Work with engineering technicians to identify and resolve recurring equipment issues.
  • Improve equipment uptime through root cause analysis and corrective actions.
  • Support preventive and predictive maintenance strategies.
  • Assist with troubleshooting drives, motors, sensors, vision systems, and servo controls.
• Data & Process Analytics
  • Develop manufacturing dashboards and reporting tools.
  • Utilize process data to identify opportunities for scrap reduction, yield improvement, and downtime reduction.
  • Support SPC initiatives and process monitoring systems.
  • Analyze process trends and provide recommendations for continuous improvement.
  • Develop automated data collection and reporting solutions.
• Project Engineering
  • Lead controls-related capital projects from concept through implementation.
  • Develop project scopes, schedules, budgets, and technical specifications.
  • Manage controls vendors, system integrators, and contractors.
  • Support FAT, SAT, commissioning, and startup activities.
  • Provide technical input during equipment procurement and design reviews.
• Process Capability & Continuous Improvement
  • Support process capability studies (Cp, Cpk, Pp, Ppk).
  • Assist with GR&R and Measurement System Analysis activities.
  • Support DOE and Six Sigma improvement projects.
  • Develop automated systems for monitoring critical process parameters.
  • Partner with process engineers to reduce variation and improve manufacturing capability.

Preferred Qualifications

• Education: Bachelor's Degree in Electrical Engineering, Controls Engineering, Automation Engineering, Mechatronics Engineering, or related engineering discipline.
• Required Experience: 3-7+ years of manufacturing controls and automation experience.
• Experience supporting high-speed manufacturing processes preferred.
• Experience leading automation or capital projects preferred.

Prysmian, as an Equal Opportunity Employer, aims to attract and recruit individuals with diverse backgrounds, skills, and abilities. We strongly believe that diversity brings significant value at all levels of the organization, increasing the possibility of capturing market opportunities and maximizing value for our customers and stakeholders. With Diversity, Equity, and Inclusion (DE&I) as part of our Social Ambition 2030 and a strategic pillar of our Company culture, Prysmian is committed to the development of an organization that prioritizes talent, where people feel respected, included, and free to fully express their potential just as they are. All Managers and HRs in Prysmian are responsible for ensuring DE&I policies are respected during the recruiting process, as well as recognizing and mitigating unconscious biases that must not influence our selection processes. All persons will be considered for employment without regard to their race, ethnicity, religion, nationality, origin, citizenship status, socio-economic status, age, sex, gender identity or expression, sexual orientation, marital status, disability, military service or veteran status, pregnancy, parental leave, medical conditions, or any other characteristic protected by applicable federal, state or local laws. Prysmian will endeavor to make a reasonable accommodation for any disclosed physical or neurological condition or disability of a qualified applicant unless the accommodation would impose an undue hardship on the operation of our business.

Prysmian is a global cabling solutions provider leading the energy transition and digital transformation. By leveraging its wide geographical footprint and extensive product range, its track record of technological leadership and innovation, and a strong customer base, the company is well-placed to capitalise on its leading positions and win in new, growing markets. Prysmian’s business strategy perfectly matches key market drivers by developing resilient, high-performing, sustainable and innovative cable solutions in the segments of Transmission, Power Grid, Electrification and Digital Solutions. Prysmian is a public company listed on the Italian Stock Exchange, with almost 150 years of experience, about 30,000 employees, 108 plants and 26 R&D centres in over 50 countries, and sales of over €15 billion in 2023.