Senior Controls Engineer

About this role

If you’re looking for a special place to build or grow your career, you’ve found it. Whether you’re an experienced professional, a recent college graduate or somewhere in between, IDEX is a place where you can apply your existing skills and learn new ones in an environment where you can make an impact.

With interesting opportunities in engineering, marketing, sales, supply chain, operations, HR, finance, and more across more than 40 diverse businesses around the globe, chances are, we have something special for you.

SUMMARY OF JOB RESPONSIBILITIES :   A Senior Manufacturing Controls Engineer is responsible for designing, implementing, and optimizing manufacturing processes to enhance efficiency, reduce waste, and ensure high-quality production. This position implements corrective actions to resolve manufacturing process problems through testing, evaluation, and analysis.

REPORTING TO : Manager, Manufacturing Engineering

DUTIES AND RESPONSIBILITIES: • Design and develop control systems for manufacturing equipment and processes. • Identify and implement corrective actions to resolve manufacturing process problems through testing, evaluation, and analysis. • Implement automation solutions to improve production efficiency and reduce costs. • Troubleshoot and correct electrical, instrumentation, and process problems associated with production equipment. PLC, HMI, and other control devices, emphasis on PLC controlled servo/stepper motors and sensor technologies. • Develop and document functional specifications for production systems including the interface between hardware and software. • Develop factory-wide sustainable standards for automation controls, hardware, software PLC&HMI, and process monitoring. • Work with cross-functional teams to ensure product designs are optimized for manufacturability and scalability. • Partner with maintenance, manufacturing engineering, operations, and quality engineering to implement process improvements, i.e. PLC & HMI program changes. • Partner with maintenance and operations to solve equipment availability (downtime) related to motor driven control elements. • Create electrical schematics and oversee the build of new industrial electrical control panels, which are NFPA79/NEC/UL508A compliant. • Participate in projects involving equipment upgrades, new installations, and process optimization. SNew Equipment Process (NEP) projects to replace, improve, and/or start manufacturing processes. • Provide technical guidance, support, and training to the manufacturing team and operations team. • Actively model IDEX values: Team, Trust, and Excellence. • Performs other related duties as assigned.

KNOWLEDGE, SKILLS, AND ABILITIES: The requirements listed below are representative of the knowledge, skills, and abilities required to perform this job successfully.  • Proficiency in PLC programming (e.g., Allen-Bradley, Siemens), SCADA systems, and industrial networking. • Proficient in Programmable Logic Controllers (PLCs) programming (Rockwell/ Allen Bradley). • Proficient in HMI program development, to include a wide range of controller generations from SLC500 to ControlLogix. • Demonstrated ability to develop Human-Machine Interfaces (HMIs) to facilitate interaction between operators and machinery. • Knowledge of industry standards and regulations to ensure compliance and maintain safety in control systems. • Knowledge of servo / stepper motor theory of operations and condition monitoring techniques. • Demonstrated ability to program and implement a variety of machine sensors (Cognex machine vision, digital, and analog devices). • Working knowledge of industrial robots and ability to develop repeatable program architecture. • Knowledge of current standards and codes as related to machine safety and fail-safe design (ISO, NFPA, NEMA, NEC, ANSI). • Demonstrated ability to connect a variety of plant and machine systems through the required communication protocols (Serial, OPC, FTP). • Demonstrated experience in Electrical AutoCad / Solidworks. Must be able to design control circuits, overload protection, create and edit machine electrical drawings. • Demonstrated experience in data analysis using basic statistical comparison techniques & Statistical Process Control (SPC). • Experience with Lean Manufacturing, Six Sigma, or similar methodologies is a plus. • Excellent communication skills, both written and verbal. • Demonstrated experience working collaboratively with key stakeholders.

EDUCATION AND EXPERIENCE:   • Bachelor’s degree in Electrical Engineering, Controls Engineering, or related field, required. • 5+ years of experience with controls, automation, electrical design, troubleshooting, and machine commissioning. • Experience with Rockwell PLCs / HMI, required. • Systems integration experience, i.e. integration of various servo, sensor and vision technologies through PLC and HMI, required.

KEY COMPETENCIES: To perform the job successfully, an individual should demonstrate the following competencies: • Safety and Security: The individual actively promotes and personally observes all safety procedures. The individual complies with Environmental, Safety, and Hazardous Communications requirements. • Operational Excellence: The individual is dedicated to providing organizational systems for measuring work. The individual seeks to reduce variances in organizational processes. • Interpersonal Skills: The individual remains open to other ideas and exhibits a willingness to try new things. • Relationships with Others: The individual works effectively with others, including superiors and colleagues. The employee exhibits a professional manner in dealing with others and works to maintain constructive working relationships. • Problem Solving: The individual participates in the continuous improvement process by attending meetings and presenting problems and possible solutions to the appropriate personnel. • Communication and Contact: The individual communicates effecti

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