Senior Engineer – Warehouse Controls Engineer

Abbott; North Chicago (IL); On-site; USD 78,000 - 156,000; Full time

Job summary

Abbott is seeking a Warehouse PLC / Controls Engineer to maintain, troubleshoot, and improve automated control systems in our North Chicago distribution center. You will focus on minimizing downtime and increasing reliability of conveyors, sorters, and material handling equipment.

The role requires 4–7+ years in PLC programming, HMI, VFDs, and industrial networks, with a preference for Allen‑Bradley experience. Travel is up to 5% as needed; on-site work in Illinois.

Qualifications

• Bachelor’s degree in engineering (Electrical or Controls Engineering preferred) or equivalent work experience.
• 4-7+ years of experience with PLC programming and troubleshooting (Prefer Allen-Bradley).
• FDA regulated manufacturing, consumer packaged goods or similar experience.
• Experience with validation or commissioning documentation.
• PLCs, HMIs, VFDs, and industrial networks (EtherNet/IP, Profibus, etc.)
• Electrical systems and control panels
• Proven ability to troubleshoot complex automation issues under time pressure.

Responsibilities

• Diagnose and resolve PLC, HMI, and control system issues impacting warehouse operations.
• Provide real-time support to operations teams to minimize downtime.
• Analyze system faults, alarms, and logs to identify root causes and implement corrective actions.
• Support troubleshooting of automation systems including conveyors, sorters, pick by light and robotics systems.
• Develop and maintain accurate as-built documentation for PLC programs, network architecture, and control systems.
• Update electrical schematics, I/O lists, and system configurations as modifications occur.
• Ensure documentation is organized, version-controlled, and easily accessible.
• Create and continuously improve standardized troubleshooting guides and procedures.
• Develop training materials and provide guidance to operators and maintenance technicians.
• Capture lessons learned from recurring issues to build robust knowledge bases.
• Identify opportunities for system improvements to enhance reliability, efficiency, and performance.

Skills

PLC programming

Troubleshooting

Allen-Bradley

HMI

VFDs

Industrial networks

Education

Bachelor’s degree in engineering

Tools

Allen-Bradley PLC

HMI software

Electrical panels

Job description

Abbott is a global healthcare leader that helps people live more fully at all stages of life. Our portfolio of life-changing technologies spans the spectrum of healthcare, with leading businesses and products in diagnostics, medical devices, nutritionals and branded generic medicines. Our 115,000 colleagues serve people in more than 160 countries.

JOB DESCRIPTION:

About Abbott

Abbott is a global healthcare leader, creating breakthrough science to improve people’s health. We’re always looking towards the future, anticipating changes in medical science and technology.

Our diagnostic solutions are used in hospitals, laboratories, and clinics around the globe. The crucial information derived from our tests, instruments and informatics systems are often the first step in patient care decision making for hundreds of health conditions from heart attacks to blood disorders to infectious diseases and cancers.

Working at Abbott

At Abbott, you can do work that matters, grow, and learn, care for yourself and family, be your true self and live a full life. You’ll also have access to:

• Career development with an international company where you can grow the career you dream of.
• Employees can qualify for free medical coverage in our Health Investment Plan (HIP) PPO medical plan in the next calendar year.
• An excellent retirement savings plan with high employer contribution
• Tuition reimbursement, the Freedom 2 Save student debt program and FreeU education benefit - an affordable and convenient path to getting a bachelor’s degree.
• A company recognized as a great place to work in dozens of countries around the world and named one of the most admired companies in the world by Fortune.
• A company that is recognized as one of the best big companies to work for as well as a best place to work for diversity, working mothers, female executives, and scientists.

The Opportunity

• This is not a remote opportunity
• Traveling up to 5%

This position works out of our Abbott Distribution Center (North Chicago), IL location in the Core Diagnostics Division.

What You’ll Work On

The Warehouse PLC / Controls Engineer is responsible for maintaining, troubleshooting, and improving automated control systems within a warehouse or distribution environment. This role focuses on maximizing system uptime through rapid issue resolution, preventive maintenance, and continuous improvement of PLC-controlled equipment such as conveyors, sortation systems, and automated material handling systems.

• Diagnose and resolve Programmable Logic Control (PLC), Human machine interface (HMI), and control system issues impacting warehouse operations.
• Provide real-time support to operations teams to minimize downtime.
• Analyze system faults, alarms, and logs to identify root causes and implement corrective actions.
• Support troubleshooting of automation systems including conveyors, sorters, pick by light and robotics systems.

System Documentation

• Develop and maintain accurate as-built documentation for PLC programs, network architecture, and control systems.
• Update electrical schematics, I/O lists, and system configurations as modifications occur.
• Ensure documentation is organized, version-controlled, and easily accessible.

Troubleshooting Guides & Knowledge Sharing

• Create and continuously improve standardized troubleshooting guides and procedures.
• Develop training materials and provide guidance to operators and maintenance technicians.
• Capture lessons learned from recurring issues to build robust knowledge bases.

Continuous Improvement & Upgrades

• Identify opportunities for system improvements to enhance reliability, efficiency, and performance.
• Propose and implement equipment upgrades, control logic enhancements, and process optimizations.
• Collaborate with vendors and engineering teams on system modifications and new installations.

Preventive & Predictive Maintenance

• Develop and execute preventive maintenance strategies for PLCs, control panels, and automation systems.
• Monitor system health and implement predictive maintenance techniques to prevent failures.
• Ensure compliance with maintenance schedules to maximize uptime and equipment lifespan.

Testing & Commissioning

• Support commissioning of new equipment, system upgrades, and retrofit projects.
• Conduct Factory and site acceptance testing (FAT/SAT) testing and validate system performance post-implementation.
• Verify proper operation of safety circuits and compliance with standards.

Required Qualifications

• Bachelor’s degree in engineering (Electrical or Controls Engineering preferred) or equivalent work experience.
• 4-7+ years of experience with PLC programming and troubleshooting (Prefer Allen-Bradley).
• FDA regulated manufacturing, consumer packaged goods or similar experience.
• Experience with validation or commissioning documentation.
• PLCs(Programmable Logic Control), HMIs(Human machine interface), VFDs (Variable Frequency Drive), and industrial networks (EtherNet/IP, Profibus, etc.)
• Electrical systems and control panels
• Proven ability to troubleshoot complex automation issues under time pressure.

Preferred Qualifications

• Warehouse automation, distribution centers, or material handling systems.
• Experience with WMS (Warehouse Management Systems) and other IT/OT systems integration.
• Working knowledge of the principles of quality software engineering as described by software lifecycle development processes that are consistent with ISO, IEEE, or other FDA recognized standards.
• Programming experience using current programming languages (C#, html, SQL) and/or experience in software development.
• Be familiar with tools within Continuous Improvement (e.g., 6 Sigma, Lean, Kaizen, etc.) and participate in problem resolution.
• Ability to manage multiple tasks and know how to prioritize the workday.
• ‘Out-of-the-box’ thinking and problem solving.

Learn more about our health and wellness benefits, which provide the security to help you and your family live full lives: www.abbottbenefits.com

Follow your career aspirations to Abbott for diverse opportunities with a company that can help you build your future and live your best life. Abbott is an Equal Opportunity Employer, committed to employee diversity.

Connect with us at www.abbott.com, on Facebook at www.facebook.com/Abbott and on Twitter @AbbottNews and @AbbottGlobal.

The base pay for this position is

$78,000.00 – $156,000.00

In specific locations, the pay range may vary from the range posted.

JOB FAMILY:

Engineering

DIVISION:

CRLB Core Lab

LOCATION:

United States > North Chicago : K02

ADDITIONAL LOCATIONS:

WORK SHIFT:

Standard

TRAVEL:

Yes, 5 % of the Time

MEDICAL SURVEILLANCE:

Not Applicable

SIGNIFICANT WORK ACTIVITIES:

Continuous sitting for prolonged periods (more than 2 consecutive hours in an 8 hour day), Keyboard use (greater or equal to 50% of the workday)

Abbott is an Equal Opportunity Employer of Minorities/Women/Individuals with Disabilities/Protected Veterans.

EEO is the Law link - English: http://webstorage.abbott.com/common/External/EEO_English.pdf

EEO is the Law link - Espanol: http://webstorage.abbott.com/common/External/EEO_Spanish.pdf