Sr. Controls Engineer New Research Triangle Park, NC

Vulcan Elements Inc.; North Carolina; On-site; USD 120,000 - 170,000; Full time

Job summary

Vulcan Elements Inc. is seeking a Senior Controls Engineer to lead controls and software integration for a massive 1 million square foot facility expansion.

You will own hardware/software interfaces for production and material handling equipment and establish site-wide automation standards. This high-ownership role requires deep expertise in industrial automation, safety programming, and integration of PLCs, HMIs, SCADA, and robotics.

Qualifications

• Bachelor’s or Master’s in electrical/automation engineering with 8+ years in industrial automation.
• Proven hands-on programming and commissioning of Siemens and Allen-Bradley PLCs and HMIs.
• Authorship of controls standards or code libraries used by other engineers.
• Deep understanding of servos, VFDs, high-speed conveyors, and automated material handling.

Responsibilities

• Lead hands-on programming, debugging, and commissioning of PLCs and HMIs for new and existing equipment.
• Define site controls standards, code libraries, and templates for consistency.
• Own ISA-88 models and batch control decisions and implementations.
• Review vendor schematics and participate in FAT/SAT testing to ensure safety and performance.
• Analyze OEE and downtime data to identify automation improvements.

Skills

PLC programming

HMI programming

ISA-88

Industrial automation

Controls standards

Ethernet/IP

Profinet

Python/C++/high-level

Education

Electrical engineering degree

Tools

Siemens PLCs

Allen-Bradley PLCs

HMI tools

Ignition

FactoryTalk

Wonderware

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 massive 1 million square foot manufacturing facility expansion. You will be 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.

Qualifications

• Bachelor’sorMastersdegree in electrical engineering, Automation Engineering, Mechatronics, or related field with 8+ years of direct industrial automation and controls engineering experience .
• Stronghandsonexperience programming and commissioning SiemensandAllenBradley/Rockwell PLCs 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.

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.