Controls System Engineer

3 weeks ago

Franklin, United States Superior Essex Full time

Job Description

Essex Furukawa strives to push the boundaries of what is possible by creating magnet wire solutions that enable our customers' innovations and exceed expectations. Our team provides products and services to some of the world's leading automotive, energy, and industrial manufacturers. With over a century of experience, Essex Furukawa is leading the charge to power new technologies in electric vehicles, grid modernization, and sustainability. 

As Controls System Engineer, you will be responsible for designing, implementing, and maintaining control systems designed to improve efficiency, reliability, and productivity in the manufacturing processes. You will work closely with cross-functional teams to analyze requirements, develop automation solutions, integrate hardware and software components, and ensure seamless operation of automated systems. In addition to providing manufacturing support, this role will also be responsible for maintaining the existing IT infrastructure and providing IT support to the entire facility.

RESPONSIBILITIES

Collaborate with project stakeholders to understand process requirements, identify opportunities for automation, and define project objectives. Design automation solutions, including hardware, software, and control systems, to meet project specifications and performance goals. Develop and implement PLC (Programmable Logic Controller) programs, SCADA (Supervisory Control and Data Acquisition) systems, and HMI (Human-Machine Interface) applications for process control and monitoring. Integrate automation systems with existing equipment, machinery, and infrastructure, ensuring compatibility and seamless communication. Specify and procure automation hardware, instrumentation, sensors, actuators, and other components required for system implementation. Conduct system testing, validation, and commissioning to ensure functionality, performance, and reliability meet design requirements. Troubleshoot automation systems, diagnose technical issues, and implement corrective actions to minimize downtime and optimize system performance. Develop and maintain documentation, including functional specifications, wiring diagrams, configuration files, and operating procedures for automation systems. Provide training and support to operators, maintenance technicians, and other personnel on the use, maintenance, and troubleshooting of automation equipment and systems. Provide general IT support to the facility in the way of troubleshooting software and hardware issues. Installing and configuring hardware and software components to ensure usability throughout the facility. Stay updated on emerging technologies, trends, and best practices in industrial automation, and recommend innovative solutions to enhance operational efficiency and competitiveness.

REQUIREMENTS

A bachelor's degree in controls engineering, automation engineering, computer science, electrical engineering, mechanical engineering, process engineering, or a related field is required for this role. Proven experience in automation and controls engineering, including designing, programming, and implementing automated systems in industrial environments. Proficiency in PLC programming languages (such as ladder logic, structured text, or function block diagram) and experience with leading PLC brands (e.g., Siemens, Allen-Bradley, Schneider Electric). Strong understanding of control systems, instrumentation, industrial networks, and communication protocols (e.g., Modbus, Profibus, Ethernet/IP). Familiarity with SCADA software, HMI development tools, and data acquisition systems for process visualization and monitoring. Experience with hardware selection, integration, and troubleshooting, including sensors, actuators, motor controls, and industrial controllers. Excellent problem-solving skills and the ability to analyze complex technical issues and implement effective solutions. Effective communication skills and the ability to collaborate with cross-functional teams, vendors, and clients to achieve project objectives. Ability to troubleshoot and fix IT issues typically found in a manufacturing facility. IT and infrastructure support responsibilities include, but not limited to: Network switch maintenance Database maintenance Server maintenance Server application maintenance Network connectivity (wired and wireless) Experience with network protocol and physical system configuration, operation, and troubleshooting SQL database design and maintenance MES maintenance and coordination with IT for updates and modifications PC work station Relevant certifications (e.g., Certified Automation Professional (CAP), Certified Control Systems Technician (CCST), PLC manufacturer certifications) are a plus.

**Note:** This job description is intended to provide a general overview of the responsibilities and requirements for an Automation Engineer position and may vary depending on the specific industry, company, or project requirements.

High degree of proficiency in at least four of the following automation technologies: Rockwell products (RSLogix5000, RSSql, function block programming) Omron (CX programmer, CX Designer) Siemens (S7) AC motor inverters (ABB, Allen Bradley, Siemens, Lenz) Loop controllers (Honeywell, Red Lion) Load/update firmware on devices Vision systems (Keyence, Cognex) Fieldbus communications and protocols (Profibus, DeviceNet, CAN bus) Experience and working knowledge of transaction management, HMI, and SCADA platforms such as RSsql, RSView, Indusoft/Ignition, Kepware, Wonderware and similar. Expert understanding of ladder logic, I/O, and network communication. Responsible for programming and deploying PLC logic, HMI, sensors, and other types of electronic devices on the process line. Mechanical-electrical system characterization, modelling, and translation into controls algorithms.  Demonstrated use of data analysis to troubleshoot and correct control systems operation. Ability to create electrical schematics in AutoCAD and supporting documentation for system quoting, construction, installation, and post commissioning as-built documentation. Ability to use hands-on tools such as oscilloscope, digital multi-meter, portable data acquisition, and similar transducers for process measurement, testing, and troubleshooting. Knowledgeable on NEC code and NFPA-70E and Arc Flash requirements. Strong cause-effect analytical abilities to solve problems. Strong verbal and written communication skills (including analysis, interpretation, & reasoning). Ability to explain moderately complex information to others in a concise manner. IT and infrastructure support Network switch maintenance Database maintenance Server maintenance Server application maintenance Network connectivity (wired and wireless) Experience with network protocol and physical system configuration, operation, and troubleshooting SQL database design and maintenance MES maintenance and coordination with IT for updates and modifications PC work station

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