Manufacturing Controls Engineer

Insight Global; Buffalo (NY); On-site; USD 90,000 - 120,000; Full time

Job summary

Insight Global is seeking a hands-on Controls Engineer for a machining-intensive, high-volume production setting. You will interpret PLC logic, troubleshoot equipment, and partner with production, quality, and maintenance teams to keep lines running smoothly.

The role emphasizes cross-functional collaboration, root-cause analysis, and continuous improvement on a Fortune 100 manufacturing platform. Flexibility to work shifts is required.

Qualifications

• Demonstrated knowledge of PLC programming (Allen-Bradley Rockwell, Siemens, Ladder Logic).
• Ability to read and troubleshoot electrical schematics.
• Bachelor’s degree in electrical/automation engineering or related field.
• In lieu of a degree, 5+ years of senior PLC programming experience.

Responsibilities

• Troubleshoot and support PLCs on the production floor, ensuring continuity of operations.
• Read ladder logic and trace faults to root causes behind machine stoppages.
• Collaborate with maintenance and operators to restore equipment and stabilize performance.
• Update PLC logic and HMI screens for process improvements and documentation.
• Contribute to capital projects, commissioning activities, and safety-driven improvements.

Skills

PLC programming

Ladder logic

Schematic reading

Robotics basics

Ethernet/IP networks

Servo drives/VFDs

Leadership

Troubleshooting

Shift flexibility

Education

Bachelor's degree in Electrical/Automation Engineering

Tools

Matrox Vision

Job description

Job Description

This Controls Engineer position supports a machining intensive, high volume production environment within a 12 person engineering team. The role requires a hands on, floor focused engineer who can quickly interpret PLC logic, troubleshoot equipment issues, and partner closely with production, quality, and maintenance. Candidates with foundational PLC experience who want to grow within a Fortune 100 manufacturing organization will thrive here.

Daily Rhythm & Communication

• Participate in multiple carry over meetings throughout the day:
  • Morning full team carry over to review previous shift issues, production status, and priorities.
  • Smaller focused carry over with the controls/maintenance group to align on technical tasks.
  • End of day carry over to document progress, flag unresolved issues, and hand off to the next shift.
• Join brief stand up meetings to discuss:
  • Top priority items for the shift
  • Equipment or processes that require monitoring
  • Any new production needs or emerging risks
• Maintain strong communication with production supervisors, operators, maintenance technicians, and quality engineers to stay aligned on daily operational goals.

Email & Shift Handoff Review

• Review emails from all three shifts to understand:
  • Hot issues that require immediate attention
  • Trends or recurring faults
  • Any equipment that is running in a degraded state
• Use this information to plan your day, prioritize troubleshooting, and prepare for upcoming production demands.

Troubleshooting & Support (50%)

• Respond to carry over issues from previous shifts, ensuring continuity of troubleshooting efforts.
• Assist maintenance with breakdowns, unplanned downtime, and chronic equipment faults.
• Connect to PLCs (Allen Bradley, Siemens, etc.) to:
  • Read and interpret ladder logic or structured text
  • Trace faults through logic paths
  • Identify root causes behind machine stoppages or inconsistent behavior
• Support operators by:
  • Observing machine behavior in real time
  • Asking targeted questions to understand symptoms
  • Coaching them on proper machine operation when needed
• Partner with maintenance to restore equipment functionality, verify repairs, and confirm that machines return to a stable state.
• Document troubleshooting steps and communicate findings to the broader team.

Project Work (50%)

• Support corrective action plans for recurring issues, including root cause analysis and implementation of permanent fixes.
• Participate in process improvement initiatives, automation upgrades, and reliability enhancements.
• Perform offline programming tasks such as:
  • Updating PLC logic
  • Modifying HMI screens
  • Testing changes in a safe, controlled environment before deployment
• Create or update electrical and controls design drawings, including panel layouts, wiring diagrams, and device schematics.
• Contribute to capital projects, equipment installations, and commissioning activities.
• Split time between:
  • Production floor work (machine observation, testing, troubleshooting)

We are a company committed to creating diverse and inclusive environments where people can bring their full, authentic selves to work every day. We are an equal opportunity/affirmative action employer that believes everyone matters. Qualified candidates will receive consideration for employment regardless of their race, color, ethnicity, religion, sex (including pregnancy), sexual orientation, gender identity and expression, marital status, national origin, ancestry, genetic factors, age, disability, protected veteran status, military or uniformed service member status, or any other status or characteristic protected by applicable laws, regulations, and ordinances. If you need assistance and/or a reasonable accommodation due to a disability during the application or recruiting process, please send a request to [e-mail] learn more about how we collect, keep, and process your private information, please review Insight Global's Workforce Privacy Policy: https://insightglobal.com/workforce-privacy-policy/.

Skills and Requirements

• 1.Demonstrated knowledge of PLC programming (Allen-Bradley Rockwell, Siemens, Ladder Logic PLC, etc.)
• 2.Ability to read/troubleshoot electrical schematics
• 3.Basic understanding of robots (ex: Fanuc, which is preferred)
• 4.Bachelors or technical program (ex: electrical engineering, automation, mechatronics, engineering technology, etc.
• a.In lieu of bachelors degree, must have 5+ years of strong, senior level PLC programming experience 5.Demonstrated problem solving and analytical skills in a high-volume manufacturing environment
• 6.Strong Comprehension of Ethernet/IP industrial networks
• 7.Prior automotive / vehicle assembly or industrial automation experience is preferred
• 8.Understanding/Programming of servo drives, motion control, and VFDs is preferred
• 9.Strong communication and interpersonal skills; able to work with maintenance, production, suppliers, and central ME teams
• 10.Leadership/ownership of tasks: planning, scheduling, and coordinating work with trades and contractors.
• 11.Basic Automation Controls Vision systems programming experience (Matrox Preferred Matrox)
• 12.Ability to work any shift as required by plant operations