Controls Engineer

The Controls Engineer is a data-driven systems specialist who leverages deep PLC expertise to identify performance trends, optimize system throughput, and provide 'surgical' technical leadership. This role combines emergency troubleshooting with long-term performance engineering, using data analysis tools such as Grafana and Looker, as well as LLMs, to solve problems and enhance site performance.

This role combines deep controls engineering expertise with front-line operational ownership , providing escalation-level troubleshooting, safe modification of PLC code, system optimization through data analysis, and mentorship of Senior and Maintenance Engineers.

The position is not purely desk-based : the successful candidate must be comfortable working on live systems, responding to critical incidents, and occasionally supporting operations at night and on weekends.

- Provide front-line and escalation support for live production control systems (PLC, SCADA, HMI, Safety PLCs)

- Diagnose and resolve complex hardware and software faults using:

- PLC code monitoring and modification (Siemens TIA Portal preferred)

- Industrial networks (e.g. Profinet, CAN bus, barcode readers)

- Implement temporary workarounds or controlled PLC changes to safely maintain operations when required.

- Ensure all changes follow change control, backup, and documentation standards.

- Perform troubleshooting and system modifications in line with electrical safety and machine safety standards.

- Maintain and troubleshoot Safety PLC systems , including interlocks, door sensors, and safety devices.

- Promote a strong safety-first culture , including incident prevention and safe response during high-risk activities

- Respond rapidly to system failures with appropriate urgency

- Drive efficient resolution while ensuring long-term reliability (not just "quick fixes")

- Collaborate with inventory teams to manage critical spare parts and minimize downtime

- Support planned maintenance and quality inspections across the site.

- Use operational KPIs (uptime/downtime, DPTOs, EPTIs, PM data, reactive events) to identify trends and weaknesses.

- Propose and implement data-driven system optimizations to improve throughput, reliability, and stability.

- Analyze complex datasets using Grafana and Looker to identify problems and systemic inefficiencies outside standard maintenance loops.

- Produce clear Root Cause Analyses (RCAs) and performance reports for stakeholders

- Communicate clearly with Engineering Managers, Operations, SMEs, CoE, and Systems Delivery teams

- Translate technical system behavior into actionable KPIs for site leadership, 'telling the story' of site performance through data.

- Own the Jira pipeline for controls-related improvements, ensuring external escalations are prioritized based on ROI and operational impact.

- Act as a technical mentor to Senior and Maintenance Engineers

- Proactively identify recurring issues and recommend preventative or design improvements

- Stay current with new tools, technologies, and best practices in automation and controls

- After 6 months, you aren't just reacting to alarms; you are predicting failures before they happen using trend analysis.

- You have become the 'technical translator' for the SEOM (Site Engineering Operations Manager), turning system logs into a clear roadmap of site improvements.

- The Maintenance teams are more effective because you have turned your findings into 'Best Practice' SOPs.

- * Associate's (bachelor's preferred) degree in Electrical Engineering (or related discipline) or equivalent experience

- 5+ years in automation/controls roles, with 3+ years in a warehouse, distribution, or industrial environment

- Control system communication protocols (WCS/WMS integration)

- Available for night and weekend work on an as-needed basis, in person or on call

- Strong analytical, problem-solving, and decision-making skills

- Desired knowledge on diagnosing, troubleshooting, and repairing printed circuit boards, using tools like soldering irons, oscilloscopes, and microscopes.

This role will require flexibility due to us being a 24/7 operation