Robotics/Controls Engineer

The Automation Controls Engineer provides hands-on technical leadership and controls engineering expertise for robotics, automation, and manufacturing systems while coordinating daily activities to support safe, reliable, and efficient production. This role serves as the primary point of contact for automation and controls priorities, communicates critical issues, and promotes effective collaboration among automation and robotics technicians, maintenance, engineering, operations, and supervision.

Success is measured through disciplined safety and LOTO practices, timely communication, project execution, and shared accountability for OEE, scrap, equipment reliability, and safety compliance.

The expected annual salary range for this role is $77,000 - $126,000 a year depending on experience. This position is also eligible for a variable incentive program.

Design, Development & Implementation

• Develop automation and controls concepts based on process requirements, manufacturing standards, and design guidelines

• Design, develop, test, and implement PLC, HMI, SCADA, motion control, and data acquisition software using Beckhoff TwinCAT and Allen-Bradley Studio 5000 platforms

• Review equipment and production concepts including safety risk assessment, mechanical design, electrical controls, robotics, vision, and industrial communications

• Select, evaluate, and integrate automation components, controls hardware, sensors, actuators, safety devices, and robotic systems (Staubli, Universal Robots, Epson)

• Support FAT, SAT, commissioning, and production release of new equipment; coordinate line moves, installations, and project handoffs

Operations, Maintenance & Troubleshooting

• Develop and maintain PLC software, HMI screens, control logic, machine diagnostics, and system alarms for new and existing equipment

• Configure and support industrial networks (EtherCAT, Ethernet/IP, Profinet, Modbus TCP) and troubleshoot servo drives, VFDs, motion systems, and safety PLCs

• Diagnose and resolve mechanical, pneumatic, electrical, communication, and control-system issues to minimize downtime

• Perform preventive maintenance including calibration, lubrication, testing, validation, and safety checks

• Lead root cause analysis and implement corrective actions to reduce repeat failures and improve MTTR, MTBF, and equipment reliability

Production Support & Continuous Improvement

• Serve as escalation point for production support and prioritize issues based on safety, quality, and production impact

• Analyze downtime, scrap, cycle time, and OEE data to identify improvement opportunities and lead efforts to meet production goals

• Support integration and optimization of AMR/AGV systems, vision systems, and automation controls

• Create and maintain automation dashboards and data visualization tools for decision-making

• Evaluate new technologies including AI-enhanced vision, advanced safeguarding, and Industry 4.0 solutions to enhance production capability and reliability

Training, Mentoring & Subject Matter Expertise

• Execute automation, robotics, and controls training based on qualification requirements

• Mentor and train technical personnel on machine maintenance, controls troubleshooting, robotics, safety, and diagnostic techniques

• Act as automation and controls subject matter expert by providing advanced troubleshooting guidance and developing troubleshooting guides and training materials

• Participate in on-call rotation supporting robotics, automation, and controls functions