Sr. Controls Engineer

Vulcan Elements; Benson (NC); On-site; USD 130,000 - 190,000; Full time

Job summary

Vulcan Elements in the United States is seeking a Senior Controls Engineer to lead controls and software integration for a massive facility expansion. You will provide technical leadership for a team of controls engineers and own the hardware/software interface of production equipment.

This role requires deep expertise in industrial automation, hands-on PLC/HMI development, and the ability to establish site-wide automation standards. Occasional travel to OEM facilities is expected.

Qualifications

• Bachelor’s or Master’s degree in electrical engineering, automation engineering, mechatronics, or related field.
• 8+ years of direct industrial automation and controls experience.
• Hands-on with Siemens and Allen-Bradley/Rockwell PLCs and HMIs.
• ISA-88 batch control: physical and procedural models, phase logic design, equipment/recipe separation.
• Deep understanding of servos, VFDs, conveyors, robotic cells, and automated material handling systems.

Responsibilities

• Lead hands-on programming, debugging, and commissioning of Siemens and Allen Bradley/Rockwell PLCs and HMIs for new and existing automation equipment.
• Develop, modify, and maintain PLC code structures, HMI screens, safety circuits, device mapping, and networking configurations.
• Own and evolve the site controls standard: code architecture, state machines, alarm and HMI conventions.
• Own the ISA-88 physical and procedural models; execute batch-engine placement study and implementation.
• Define safety PLC and functional safety conventions with EHS and equipment vendors.
• Support integration and commissioning of robotics, vision systems, AGVs, conveyors, and motion control systems.
• Configure and maintain communications between PLCs/HMIs and higher-level systems (SCADA); own the controller-side data interface.
• Review vendor electrical schematics, controls architectures, and PLC/HMI logic; support FATs and SATs.
• Serve as a senior escalation point for diagnosing complex automation issues.
• Analyze OEE, downtime data, and SCADA/MES insights to identify automation improvements.

Skills

Siemens PLC programming

Allen-Bradley PLC

HMI development

Industrial automation

SCADA/MES integration

Electronic networking

Education

Bachelor's or Master’s in Electrical/Automation/Mechatronics

Tools

Siemens PLC

Allen-Bradley/Rockwell PLC

HMI platforms

SCADA systems (Ignition, FactoryTalk, Wonderware)

ISA-88 batch control

Industrial communication protocols (Ethernet/IP, Profinet, EtherCAT, OPC UA, Modbus)

Job description

Job Description

Vulcan Elements is manufacturing American rare-earth permanent magnets for a secure, resilient future. With a focus on national security and economic resiliency, we serve critical industries such as defense, aerospace, and automotive powering a high-technology future. Vulcan Elements is building a team of ambitious professionals committed to Mission Focus, Technical Excellence, and Transparency.

As the Senior Controls Engineer you will lead the controls and software integration for a massive1 million square foot manufacturing facilityexpansion. You willbe responsible fortechnicalleadership ofa team of controls engineers,establishingsite-wide automation standards, and owning the hardware/software interface of all production and material handling equipment. This is a high-impact, high-ownership leadership role requiring deep technicalexpertisein industrialautomation.Domesticand international travel to OEM facilities up to ~20% during test campaigns.

Responsibilities

• Lead hands-on programming, debugging, and commissioning of Siemens and Allen Bradley/Rockwell PLCs and HMIs for new and existing automation equipment.
• Develop,modify, andmaintainPLC code structures, HMI screens, safety circuits, device mapping, and networking configurations to ensure robust and standardized automation performance across all equipment.
• Own and evolve the site controls standard: code architecture, state machines,alarmand HMI conventions. Author the controls specification issued with every OEM equipment package and build the templates and code libraries that let area engineers and integrators execute consistently.
• Own the ISA-88 physical and procedural models; execute the batch-engine placement study (PLC-resident vs. supervisory vs. MES-driven), decision, and implementation.
• Define safety PLC and functional safety conventions (ISO 13849 performance levels, SIL-rated loops) with EHS and equipment vendors.
• Support the integration and commissioning of robotics, vision systems, AGVs, conveyors, and motion control systems—including servos and VFDs-to enable seamless material flow and highreliability production operations.
• Configure andmaintaincommunications between PLCs/HMIs andhigherlevelsystems (SCADA).Own the controller-side data interface-exposed tags, handshakes, and the phase-logic contract-to the supervisorylayers
• Review vendor electrical schematics, controlsarchitectures, and PLC/HMI logic. Hold code review and acceptance authority for all delivered OEM PLC code.Support Factory Acceptance Tests (FATs) and Site Acceptance Tests (SATs) to ensure full compliance with functional and safety requirements.
• Serve as a senior-level escalation point for diagnosingcomplex automation issues involving networks, motion systems, instrumentation, and industrial communication protocols.
• Analyze OEE, downtime data, and SCADA/MESinsights toidentifyand implement automation improvements that increase throughput, safety, and reliability.

• PLC code architecture, HMI screens, vision inspection programs, tag databases, MES/SCADA transaction lists, network IP lists, password inventories, and system backups.
• Controls risk assessments, interlock/guarding logic, andsafetyratedPFMEA inputs.
• Controls layouts, network topology layouts, station cycle times, sequence diagrams, and automation simulations.
• Electrical schematics, pneumatic drawings, controls panel layouts, and industrial network architecture.
• Controls standard revisions, OEM controls specifications, code library and template releases, and the batch-engine placement study.

Responsibilities and tasks outlined are not exhaustive and may change asdeterminedby the needs of the business

Qualifications

• Bachelor'sorMastersdegree in electrical engineering, Automation Engineering, Mechatronics, or related field with8+ years of direct industrial automation and controls engineering experience.
• Stronghandsonexperience programming and commissioningSiemensandAllenBradley/RockwellPLCs and HMIs.
• Demonstratedauthorship of controls standards, specifications, or code libraries used by other engineers and vendors. ISA-88 batch control: physical and procedural models, phase logic design, equipment/recipe separation.
• Deep understanding of servos, VFDs, highspeed conveyors, robotic cells, and automated material handling systems.
• Safety PLC programming competence and ISO 13849 / IEC 62061 interlock design judgmentwiththe discipline to accept, reject, and defenddecisionstoOEMswith varying standards.
• Proficiencywith Ethernet/IP,Profinet,EtherCAT, OPCUA,Modbus, serial,and similar industrial communication standards.

Must be a U.S. Person due to required access to U.S. export-controlled information or facilities

Preferred Skills

• Working experience with multi - axis robotic systems (Fanuc, Kuka, ABB) and machine vision platforms (Cognex, Keyence)
• Experience in heavy industrial, greenfield, chemical, or metallurgical manufacturing environments.
• Experience developing SCADA applications in Ignition,FactoryTalk,Wonderware, or similar platforms.
• AGVinfrastructure design and integrationexperience
• Familiarity with Python, C++, or otherhighlevellanguages for automation or data analytics.
• Experience in regulated industries such as Defense, Aerospace, or Automotiveand/or Batch/Hybrid processes (chemicals, materials, metals, pharma)

Physical and Environmental Requirements

The position requires regular presence on the production floor and the ability to navigate all areas of the facility. Candidates must be able to climb stairs, stand and walk for extended periods, and work in environments that may be hot, humid, or noisy. The role also requires the use of personal protective equipment, including respirators, and adherence to all applicable safety policies, procedures, and regulatory requirements. Employees must be able to complete required fit testing, wear appropriate PPE for the duration of assigned tasks, and respond safely to changing conditions within the production environment.