Sr. Controls Engineer

About the role

Vulcan Elements is seeking a highly experienced Senior Controls Engineer to take a lead role in automation acceptance, commissioning, and integration for a major expansion project at a large manufacturing facility. The successful candidate will be responsible for managing the entire automation acceptance process for OEM equipment, ensuring that all systems meet project specifications, safety standards, and quality requirements. This position requires a strong technical background in industrial automation, extensive hands-on experience with PLC and HMI programming, and the ability to coordinate across multiple vendors and teams. The role involves working closely with engineering, quality, and manufacturing teams to deliver reliable, efficient automation solutions that support the plant's operational goals.

Key facts

What you'll do

• Lead the programming, debugging, and commissioning of Siemens and Allen Bradley/Rockwell PLCs and HMIs for both new automation systems and existing equipment upgrades.
• Develop, modify, and maintain PLC code structures, HMI interfaces, safety circuits, device mappings, and network configurations to ensure consistent and reliable automation performance across all equipment.
• Review vendor electrical schematics, control architectures, and PLC/HMI logic to verify compliance with project standards and operational requirements.
• Manage the Factory Acceptance Testing (FAT) and Site Acceptance Testing (SAT) campaigns by developing detailed acceptance protocols covering PLC logic, HMI alarms, interlock validation, network security, and system integration.
• Document all as-tested code, configuration baselines, punch list items, and commissioning activities to ensure traceability and compliance with project documentation standards.
• Collaborate with the Quality team to develop validation protocols that align with manufacturing standards and meet regulatory or internal quality requirements.
• Support the integration and commissioning of robotics, vision systems, Automated Guided Vehicles (AGVs), conveyors, and motion control systems to optimize material flow and production efficiency.
• Configure and troubleshoot communication between PLCs/HMIs and higher-level systems such as Manufacturing Execution Systems (MES) and Supervisory Control and Data Acquisition (SCADA) platforms.
• Develop and troubleshoot SCADA tags, transactions, alarms, and data acquisition points to ensure seamless data flow and system monitoring.
• Serve as a senior technical resource for diagnosing and resolving complex automation issues involving networks, motion systems, instrumentation, and industrial communication protocols.
• Work closely with vendors, contractors, and internal teams to ensure timely resolution of punch items and system issues during commissioning phases.
• Maintain detailed records of code versions, configuration changes, acceptance documentation, and commissioning evidence for audit and validation purposes.
• Participate in design reviews, risk assessments, and safety evaluations related to automation systems to ensure compliance with safety standards and best practices.
• Provide technical guidance and mentorship to junior controls engineers and technicians involved in the project.
• Support ongoing improvements and troubleshooting efforts during the operational phase of the plant, ensuring system stability and performance.

Requirements

• Bachelor's or Master's degree in Electrical Engineering, Automation Engineering, Mechatronics, or a closely related field.
• Minimum of 7 years of hands-on experience in industrial automation, controls engineering, or related roles.
• Extensive experience programming, commissioning, and troubleshooting Siemens and Allen Bradley/Rockwell PLCs and HMIs in a manufacturing environment.
• Proven ability to manage multi-vendor acceptance campaigns, including developing acceptance protocols, maintaining disciplined change control, and resolving punch list items efficiently.
• Strong technical documentation skills, capable of producing clear, detailed reports, and validation documentation for vendors, auditors, and internal teams.
• Deep knowledge of servos, Variable Frequency Drives (VFDs), high-speed conveyors, robotic systems, and automated material handling solutions.
• Familiarity with industrial communication standards such as Ethernet/IP, Profinet, EtherCAT, OPCUA, Modbus, and serial communication protocols.
• Ability to work effectively in a fast-paced, team-oriented environment, managing multiple priorities and deadlines.
• Strong problem-solving skills and the ability to diagnose complex automation issues involving networks, motion, and instrumentation.
• Excellent communication skills, both written and verbal, to coordinate with vendors, contractors, and internal stakeholders.
• Experience working in regulated industries or environments with strict validation requirements is a plus.

Nice to have

• Prior experience as a commissioning-focused controls engineer at a system integrator or OEM, with a background in writing machine code and accepting third-party work.
• Practical experience with multi-axis robotic systems from manufacturers such as Fanuc, Kuka, or ABB.
• Knowledge of machine vision platforms like Cognex or Keyence.
• Experience working in heavy industrial, chemical, or metallurgical manufacturing sectors.
• Skills in developing SCADA applications using platforms such as Ignition, FactoryTalk, or Wonderware.
• Familiarity with AGV systems and their integration into manufacturing processes.
• Programming skills in high-level languages such as Python or C++ for automation, data analytics, or system integration tasks.
• Experience working in regulated environments such as Defense, Aerospace, or Automotive, with familiarity with GAMP 5 or computer system validation standards.

Skills & tools

• PLC programming (Siemens, Allen Bradley/Rockwell)
• HMI development and troubleshooting
• Control system design and integration
• Network configuration and troubleshooting (Ethernet/IP, Profinet, EtherCAT, etc.)
• Robotics and motion control systems
• SCADA development and data acquisition
• Validation and documentation processes
• Safety circuit design and validation
• Troubleshooting complex automation issues involving instrumentation and communication protocols

Practical notes

Candidates must be U.S. Persons due to the necessity for access to U.S. export-controlled information or facilities. The role may require domestic and international travel, potentially up to 50% during testing and commissioning phases. Candidates should be prepared to work on-site in Research Triangle Park, NC, and be comfortable with the demands of large-scale industrial automation projects. The position involves working closely with multiple teams and vendors to ensure successful project delivery and system performance.