Senior Controls Engineer

First Quality King of Prussia PA; McElhattan (Clinton County); On-site; USD 110,000 - 150,000; Full time

Benefits offered by this job

Competitive pay

Bonus opportunities

Paid time off

Medical benefits

Dental & vision

401(k) match

Parental leave

Dependant care FSA

Tuition assistance

Wellness program

Job summary

First Quality in McElhattan, PA, seeks a Senior Controls Engineer to design, implement and upgrade complex production controls across our manufacturing equipment. You will develop PLC/DCS solutions, specify hardware, and drive data collection for performance tracking.

The ideal candidate has 8+ years' experience with Industrial Controls, strong PLC/HMI skills, AutoCAD, and Lean Six Sigma knowledge. Join a team focused on safety, reliability, and continuous improvement.

Qualifications

• Bachelor’s degree in Electro‑Mechanical Engineering, Electrical Engineering, Mechatronics, Automation, Robotics or Manufacturing Engineering.
• Minimum of 8 years’ experience with Industrial Controls Systems.
• Advanced knowledge of PLC‑based hardware and software (Rockwell and Siemens), servo control, and HMI.
• Ability to create/modify schematic drawings using AutoCAD.
• Lean Six Sigma Green Belt or Black Belt preferred.
• Security in Automation ISO 62443 knowledge or training preferred.

Responsibilities

• Collaborate with engineering, maintenance, and production to design, install, and commission new equipment and process controls.
• Specify and design DCS/PLC/HMI, servo systems, sensors, and data collection per FQ standards.
• Troubleshoot equipment; lead and mentor Controls team and technicians.
• Work with MES team to develop machine data collection and track performance.
• Lead small capital projects and stay current with safety and control technologies.

Skills

Electrical Engineering

Mechatronics

Automation

PLC Programming

HMI/SCADA

Schematic drawings

Education

Bachelor's in Electro-Mechanical / Electrical / Mechatronics

Tools

AutoCAD

Rockwell PLC

Siemens PLC

Servo systems

Job description

Senior Controls Engineer

Founded over 35 years ago, First Quality is a family‑owned company that has grown from a small business in McElhattan, Pennsylvania into a group of companies, employing over 5,000 team members, while maintaining our family values and entrepreneurial spirit. With corporate offices in New York and Pennsylvania and eight manufacturing campuses across the U.S. and Canada, the companies within the First Quality group produce high‑quality personal care and household products for large retailers and healthcare organizations. Our personal care and household product portfolio includes baby diapers, wipes, feminine pads, paper towels, bath tissue, adult incontinence products, laundry detergents, fabric finishers, and dishwash solutions. In addition, we manufacture certain raw materials and components used in the manufacturing of these products, including flexible print and packaging solutions. Guided by our values of humility, unity, and integrity, we leverage advanced technology and innovation to drive growth and create new opportunities. At First Quality, you’ll find a collaborative environment focused on continuous learning, professional development, and our mission to Make Things Better®.

We are seeking a Senior Controls Engineer for Nutek Disposables located in McElhattan, PA. This position will be responsible for designing, implementing, and upgrading complex controls systems and software programming on production equipment and associated machinery. Provides mentorship and assists Controls Engineers and Technicians in solving complex problems. Will have a direct link to plant performance results through machine improvements and engineering‑based upkeep.

Primary Responsibilities

• Collaborates with internal Engineering Teams, Maintenance and Production personnel, OEMs, vendors, and contractors to design, install, commission, and start up new equipment and process controls. This includes electrical and controls component selection and approval, electrical design approval, software assessments & modifications, machine acceptance testing and problem identification and resolution.
• Responsible for specifying and/or designing DCS’s, PLC’s, HMI’s, servo systems, motors, drives, sensors, vision sensors, and data collection systems based on the FQ controls standards criteria.
• Evaluates electrical equipment from multiple sources and recommends the best solution for use.
• Assesses, designs, and makes complex program modifications in DCS’s, PLC logic, HMI programs and servo controller logic to improve individual equipment and overall system performance.
• Performs high level troubleshooting, in‑depth critical thinking, and utilizes all internal & external resources to solve any electrical, mechanical, or process problem.
• Leads & assists others in troubleshooting equipment, controls components and control programs.
• Works with internal MES team to develop and maintain machine data collection within the business.
• Ability to lead small capital projects.
• Expected to keep abreast of new controls technologies, industry trends, health and safety regulations and standards that affect current operations.
• Proactively identifies opportunities to increase production operation performance.
• Initiates, leads, and oversees improvement projects through completion.
• Provides technical and operation training to Controls team, Production, Warehouse, and other personnel as needed.
• Shares knowledge and techniques with team members and coordinates the training of personnel to enhance troubleshooting skills.
• Demonstrates a sense of urgency with peers and operations personnel to maintain focused actions.
• Drives a zero‑loss time mentality with team through continuous improvement practices.
• Keeping safety as the priority when making decisions.
• Provides direction and assistance as necessary for off‑shift/afterhours support.

Communication / Collaboration Responsibilities

• Collaborates with Maintenance, Process Engineering, Project Engineering, and Operations to define design requirements, design improvements, and install machinery and upgrades.
• Verifies communication of machine and process changes to all affected team members.
• Supports team with all key initiatives, special projects and provides exceptional customer service.
• Participates, facilitates, and leads communication in group settings and/or meetings.

Ideal Candidate

• Bachelor’s degree in the following degrees or related degrees: Electro‑Mechanical Engineering, Electrical Engineering, Mechatronics, Automation Engineering, Robotics Engineering, Manufacturing Engineering.
• Can create and modify schematic drawings using AutoCAD software.
• Minimum of 8 years’ experience with Industrial Controls Systems.
• Advanced knowledge of electrical theory and principles of operation.
• Advanced knowledge of PLC based hardware and software (Rockwell and Siemens), Servo Control, and HMI.
• Knowledge of Mechanical, Pneumatic, and Hydraulic systems.
• Formal Training in Functional Machine Safety and proper safe machine design through Safety Risk Assessment.
• Knowledge or formal training in Security in Automation (ISO 62443).
• Lean Six Sigma Green Belt or Black Belt (preferred but not required).
• Root Cause Analysis Experience (preferred but not required).

What We Offer You

• Competitive base salary and bonus opportunities.
• Paid time off (three‑week minimum).
• Medical, dental and vision starting day one.
• 401(k) with employer match.
• Paid parental leave.
• Child and family care assistance (dependent care FSA with employer match up to $2500).
• Bundle of joy benefit (year's worth of free diapers to all team members with a new baby).
• Tuition assistance.
• Wellness program with savings of up to $4,000 per year on insurance premiums ...and more!

First Quality is an Equal Opportunity employer. All qualified applicants will receive consideration for employment without regard to race, color, religion, sex, national origin, disability, sexual orientation, gender identification, or protected Veteran status.

Founded over 35 years ago, First Quality is a family‑owned company that has grown from a small business in McElhattan, Pennsylvania into a group of companies, employing over 5,000 team members, while maintaining our family values and entrepreneurial spirit. With corporate offices in New York and Pennsylvania and eight manufacturing campuses across the U.S. and Canada, the companies within the First Quality group produce high‑quality personal care and household products for large retailers and healthcare organizations. Our personal care and household product portfolio includes baby diapers, wipes, feminine pads, paper towels, bath tissue, adult incontinence products, laundry detergents, fabric finishers, and dishwash solutions. In addition, we manufacture certain raw materials and components used in the manufacturing of these products, including flexible print and packaging solutions. Guided by our values of humility, unity, and integrity, we leverage advanced technology and innovation to drive growth and create new opportunities. At First Quality, you’ll find a collaborative environment focused on continuous learning, professional development, and our mission to Make Things Better®.