Principal Controls Engineer – ASRS

Intellectt Inc; Libertyville (IL); On-site; USD 95,000 - 120,000; Full time

Job summary

A leading engineering firm is seeking a highly experienced Controls Engineer to provide support for automated storage and retrieval systems (ASRS). The ideal candidate will possess 10–15 years of controls engineering experience, with specific expertise in PLC programming and troubleshooting in automated environments. This role involves collaboration with various teams to ensure operational efficiency and compliance with safety standards.

Qualifications

• 10–15 years of experience in controls engineering within automated environments.
• Proven experience with ASRS shuttle systems and pallet/tote-handling automation.
• Advanced troubleshooting skills in high-speed operations.

Responsibilities

• Provide senior-level controls engineering support for ASRS.
• Troubleshoot and optimize PLCs and automated equipment.
• Collaborate with various teams for seamless integration of systems.

Skills

PLC programming

Controls engineering

Troubleshooting

Safety systems

Communication skills

Education

Bachelor’s degree in Electrical Engineering

Tools

Siemens PLC

Allen-Bradley PLC

Job description

Job Title

Controls Engineer – Automated Storage & Retrieval Systems (ASRS)

Duration

12+ Months - Onsite

About the Role

Our client is seeking a highly experienced Senior Controls Engineer (SME level) to support, maintain, and optimize Shuttle-based ASRS systems for tote and pallet handling (non-Kardex). This role is essential for ensuring high system uptime, improving automation reliability, and driving continuous improvement across a large-scale automated warehouse environment.

The ideal candidate will bring 10–15 years of experience, advanced technical expertise in controls engineering, PLC programming, and deep exposure to multiple ASRS warehouse management systems.

Key Responsibilities

• Provide senior-level controls engineering support for Shuttle-based ASRS warehouse systems (totes and pallets).
• Troubleshoot, maintain, and optimize PLCs, SCADA systems, conveyors, shuttles, and other automated material-handling equipment.
• Collaborate with operations, maintenance, IT, and warehouse engineering teams to ensure seamless integration between ASRS, WCS, and WMS platforms.
• Lead root‑cause analysis and develop long‑term corrective actions for recurring system or controls issues.
• Support system commissioning, testing, upgrades, and modifications to ASRS equipment and controls.
• Create, update, and maintain electrical schematics, control system documentation, and programming logic.
• Ensure compliance with safety, regulatory, and operational standards.
• Partner with OEMs, integrators, and vendors to resolve complex technical issues and enhance system performance.
• Provide SME‑level guidance for future automation expansions, retrofits, and facility upgrades.

Qualifications & Skills

• Bachelor’s degree in Electrical Engineering, Mechatronics, Controls Engineering, or related field (or equivalent experience).
• 10–15 years of experience in controls engineering within automated warehouse or manufacturing environments.
• Proven experience with ASRS shuttle systems (non‑Kardex), conveyors, pallet/tote‑handling automation, and large automated distribution facilities.
• Strong hands‑on PLC programming experience (Siemens, Allen‑Bradley, or similar).
• Knowledge of industrial communication protocols such as Profinet, EtherNet/IP, OPC, etc.
• Experience with WCS/WMS integration and related warehouse automation technologies.
• Advanced troubleshooting skills in high‑speed, high‑availability automated operations.
• Strong understanding of safety systems (interlocks, E‑stops, safety PLCs, functional safety requirements).
• Ability to work in a fast‑paced, 24/7 operations environment, including on‑call or shift‑based support.
• Excellent communication and cross‑functional collaboration skills.