PLC Programmer / Controls Engineer

United Pharma; Kentucky; On-site; USD 90,000 - 120,000; Full time

Job summary

United Pharma is seeking an experienced PLC Programmer / Controls Engineer to support pharmaceutical and biotechnology manufacturing environments. The role focuses on PLC programming, controls integration, troubleshooting, commissioning, and qualification within GMP facilities.

The ideal candidate has hands-on experience with Siemens and/or Allen-Bradley platforms, HMIs/SCADA, and a track record delivering compliant control systems in regulated settings.

Qualifications

• Bachelor's degree in Electrical Engineering, Automation Engineering, Controls Engineering, Computer Engineering, or related field.
• 5+ years hands-on PLC programming and controls engineering experience in regulated environments.
• Experience with Pharmaceutical, Biotechnology, Medical Device, or Life Sciences manufacturing environments.

Responsibilities

• Develop, modify, troubleshoot, and maintain PLC-based control systems in pharmaceutical/biotech operations.
• Program and configure Siemens PLCs and Rockwell/Allen-Bradley PLCs.
• Develop and modify PLC logic, interlocks, alarms, and control strategies.
• Support integration with HMIs, SCADA, DCS, MES, BMS, and other automation platforms.
• Review control system designs, electrical drawings, and I/O documentation.
• Translate requirements into PLC programming and control-system functionality.
• Perform PLC troubleshooting, debugging, and root-cause analysis.
• Support FAT, SAT, commissioning, startup, and qualification activities.

Skills

PLC programming

Controls engineering

GMP/GxP

Siemens / Rockwell

HMI/SCADA

Education

Bachelor's degree in Electrical/Automation/Controls Engineering

Tools

Rockwell Studio 5000

RSLogix 5000

Siemens STEP 7

TIA Portal

WinCC

FactoryTalk View

DeltaV

Job description

We are seeking an experienced PLC Programmer / Controls Engineer with strong hands‑on experience supporting pharmaceutical, biotechnology, or other regulated Life Sciences manufacturing environments.

The ideal candidate will have demonstrated expertise in PLC programming, controls system integration, troubleshooting, commissioning, and qualification within GMP-regulated facilities. Experience with Siemens and/or Rockwell Automation (Allen-Bradley) PLC platforms is highly preferred.

The consultant will support automation and controls activities associated with manufacturing equipment, process systems, facility utilities, and production infrastructure. The role will involve working closely with Automation, Engineering, Manufacturing, Validation, Quality, and external equipment vendors to deliver reliable and compliant control systems.

Note: The client is headquartered/based in Ohio; the specific project location will be disclosed at a later stage.

Key Responsibilities

• Develop, modify, troubleshoot, and maintain PLC-based control systems supporting pharmaceutical and biotechnology manufacturing operations.
• Program and configure Siemens PLCs and/or Rockwell Automation / Allen-Bradley PLCs.
• Develop and modify PLC logic, sequences, interlocks, alarms, permissives, and control strategies.
• Support integration of PLC systems with HMIs, SCADA, DCS, MES, BMS, and other automation platforms.
• Review control system designs, functional specifications, I/O documentation, electrical drawings, and equipment documentation.
• Translate equipment and process requirements into PLC programming and control-system functionality.
• Perform PLC troubleshooting, debugging, and root‑cause analysis for automation and equipment issues.
• Support FAT, SAT, commissioning, startup, and qualification activities.
• Participate in equipment integration and controls‑system commissioning within GMP manufacturing environments.
• Develop, review, and execute controls‑related test protocols and documentation.
• Support IQ/OQ/PQ and other validation activities associated with automated systems.
• Ensure automation systems comply with applicable GMP, GxP, FDA, and data‑integrity requirements.
• Work with Validation and Quality teams to ensure computerized/automated systems meet applicable regulatory expectations.
• Troubleshoot PLC hardware, I/O modules, communication networks, instrumentation, and field devices.
• Support industrial communication protocols including EtherNet/IP, Profinet, Profibus, Modbus TCP/IP, OPC, and similar technologies.
• Configure and troubleshoot HMIs and operator interfaces.
• Review and update P&IDs, electrical drawings, control narratives, cause‑and‑effect matrices, I/O lists, and functional specifications.
• Collaborate with equipment OEMs and system integrators during installation, commissioning, and startup.
• Support automation change controls, deviations, CAPAs, and technical investigations when required.
• Maintain accurate engineering and automation documentation throughout the project lifecycle.
• Provide technical support during manufacturing operations and resolve automation‑related issues in a timely manner.
• Follow site safety procedures, engineering standards, GMP requirements, and project‑specific procedures.

Required Qualifications

• Bachelor's degree in Electrical Engineering, Automation Engineering, Controls Engineering, Computer Engineering, or a related technical discipline; equivalent experience may be considered.
• 5+ years of hands‑on PLC programming and controls engineering experience.
• Strong experience working within Pharmaceutical, Biotechnology, Medical Device, or other Life Sciences manufacturing environments.
• Hands‑on experience with at least one major PLC platform, preferably:
• Rockwell Automation / Allen‑Bradley ControlLogix
• CompactLogix
• Strong understanding of PLC programming, troubleshooting, controls architecture, and industrial automation.
• Experience with HMI/SCADA systems.
• Experience with equipment integration, commissioning, startup, and troubleshooting.
• Understanding of GMP/GxP‑regulated environments.
• Experience supporting FAT/SAT and commissioning activities.
• Ability to read and interpret electrical schematics, P&IDs, I/O drawings, and control‑system documentation.
• Strong troubleshooting and problem‑solving capabilities.
• Excellent communication and collaboration skills.

Preferred Qualifications

• Experience with both Siemens and Rockwell/Allen‑Bradley platforms.
• Experience with Siemens TIA Portal, Step 7, WinCC, PCS 7.
• Experience with Rockwell Studio 5000, RSLogix 5000, FactoryTalk View, and FactoryTalk Historian.
• Experience with Emerson DeltaV or other DCS platforms.
• Experience with Ignition, Wonderware/AVEVA, or other SCADA platforms.
• Experience with MES integration.
• Experience with pharmaceutical process equipment and manufacturing systems.
• Experience with CIP/SIP, bioreactors, chromatography, filtration, formulation, filling, packaging, or other biopharmaceutical process systems.
• Experience with facility and utility automation systems.
• Knowledge of 21 CFR Part 11, GAMP 5, Annex 11, and computerized system validation concepts.
• Experience working with validated automation systems in GMP facilities.
• Experience with industrial networking and communication protocols.
• Experience developing or reviewing URS, FRS, DS, test scripts, traceability matrices, and validation documentation.