Senior Controls Engineer

Exela Pharma Sciences; Lenoir (NC); On-site; USD 110,000 - 140,000; Full time

Job summary

Exela Pharma Sciences is seeking a Senior Controls Engineer to design, install, and service process control systems across a multi-site manufacturing environment in Lenoir, NC, US. The role emphasizes automation, data-driven improvements, and electrical design support for capital projects.

The candidate will troubleshoot PLCs (Allen-Bradley and Siemens), develop electrical schematics, and mentor junior engineers while supporting startup activities and regulatory compliance requirements.

Qualifications

• Bachelor’s degree in engineering, computer science or related discipline; 10+ years of relevant experience.
• HMI/SCADA design experience with Wonderware, Ignition, and Allen-Bradley systems.
• Knowledge of industrial networks (Ethernet/IP, EtherCAT, BacNet, Modbus).
• Familiarity with FDA, ISO, EU, ICH guidelines and 21 CFR Part 11.

Responsibilities

• Design, develop, evaluate, and improve manufacturing methods, controls, devices, and systems.
• Troubleshoot Allen-Bradley PLCs (500, RSLogix, MicroLogix, CompactLogix, ControlLogix) and Siemens PLCs.
• Lead process changes, automation projects, and equipment installation at multiple locations, including international sites.
• Develop and maintain electrical and control schematics; ensure safety and regulatory compliance.
• Provide commissioning, start-up, and ongoing maintenance support at multiple facilities; mentor junior engineers.

Skills

HMI/SCADA design

Industrial networks

Allen-Bradley VFDs/servos

Vision systems (Cognex/Keyence)

Electrical schematics reading

Fault finding/troubleshooting

Project leadership

Regulatory compliance (FDA/ISO)

Education

Bachelor’s degree in engineering/related

Tools

Wonderware

Ignition

Allen-Bradley ME-S E

Job description

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Engineering Manufacturing Lenoir, NC, US

2 days ago Requisition ID: 2079

Position Summary:

The Senior Controls Engineer will be responsible for installing, modifying, and servicing process control systems throughout the facility as well as providing electrical engineering support that consists of electrical designs and drawings. The individual will work in a high performance, team-centered work environment to support operations, engineering, and maintenance by driving continuous improvement in the automation and control of the manufacturing processes as well as providing electrical engineering. The Sr. Controls Engineer will utilize data management skills, PLC (Programmable Logic Control) skills, electrical engineering, and general troubleshooting skills to solve complex manufacturing processes, create enhancements to the process control systems, and provide electrical design solutions. The individual will assist with programming and installing of new equipment during start-up of manufacturing activities.

Job Responsibilities:

• Design, develop, evaluate, and improve manufacturing methods, controls, devices, and systems to enhance overall productivity and reduce downtime
• Troubleshoot and work with Allen-Bradley PLCs (500, RS Logix, Micro Logix, Compact Logix, Control Logix) and Siemens PLC programming to ensure optimal system performance
• Identify, research, and resolve issuesrelated to scrap, downtime, and equipment deficiencies to improve process reliability
• Lead the implementation of process changes, new automation projects, and installation of new equipment at various locations, including internationally
• Collaborate with cross-functional teams, including manufacturing, maintenance, quality, and operations, to address equipment performance issues and optimize plant processes
• Develop and maintain electrical and control schematics while ensuring compliance with safety and regulatory standards
• Provide technical support for system commissioning, start-ups, and ongoing maintenance both locally at multiple facilities
• Mentor junior controls engineers to teach correct engineering practices
• Periodically review technology advancements to provide a competitive advantage through continued education, seminars, and trade shows to provide a competitive advantage
• Work independently on assignments of medium to high complexity projects / engineering tasks applying engineering knowledge of assignments
• Responsible for managing and implementing capital projects
• Perform other duties as assigned

Required Skills:

• HMI\SCADA design experience using Wonderware, Ignition and Allen Bradley ME- SE
• Knowledge of common industrial networks (Ethernet IP, Ethercat, Bacnet and modbus)
• Knowledge of Allen Bradley VFDs and servos systems
• Knowledge of Cognex and Keyence Vision systems
• Comfortable walking down control system diagrams and red lining them to reflect as built conditions.
• Ability to read Process & Instrumentation Drawings is a plus
• Detail Oriented
• Highly Organized
• Team player who can adapt well to engineering standards
• Understanding and feedback of Input / Output control sequence
• Familiarity with current industry practices and guidelines including those required / outlined by the FDA, ISO, EU and ICH.Understand 21 CFR Part 11, cGAMP, and other regulatory guidance associated with computer / automation based systems
• Ability to read electrical schematics
• Low-voltage electrical design and layout.
• Strong technical writing and communication skills
• Strong electrical and mechanical troubleshooting skills
• Knowledge of Fanuc, ABB and Staubli robots a plus

Education and Experience Requirements:

• Bachelor’s degree in engineering, Computer Science or related discipline, with a minimum of 10 years of relevant experience