Sr. Controls Engineer

About this role

Vulcan Elements is manufacturing American rare-earth permanent magnets for a secure, resilient future. With a focus on national security and economic resiliency, we serve critical industries such as defense, aerospace, and automotive powering a high-technology future. Vulcan Elements is building a team of ambitious professionals committed to Mission Focus, Technical Excellence, and Transparency.

As the Sr. Controls Engineer (FAT/CSV) you will lead automation acceptance and commissioning for a massive 1 million square foot manufacturing facility expansion. You will own the automation acceptance thread across a large OEM equipment campaign - authoring standardized FAT/SAT protocols, running the program-wide punch register; writing, modifying, and troubleshooting PLC code from punch-item fixes through commissioning and a share of live controls support. This is a high-impact, high-ownership role requiring deep technical expertise in industrial automation. Domestic and international travel to OEM facilities up to ~50% during test campaigns.

This role begins in Durham, NC and is expected to move to Benson, NC upon completion of new facility.

Responsibilities

• Lead hands-on programming, debugging, and commissioning of Siemens and Allen Bradley/Rockwell PLCs and HMIs for new and existing automation equipment.

• Develop, modify, and maintain PLC code structures, HMI screens, safety circuits, device mapping, and networking configurations to ensure robust and standardized automation performance across all equipment.

• Execute the scaling-equipment design-review campaign, converting findings into hardened, detailed technical deliverables for OEM vendors.

• Review vendor electrical schematics, controls architectures, and PLC/HMI logic. Own the FAT/SAT campaign: author standardized acceptance protocols, covering PLC logic conformance, HMI/alarm acceptance, interlock validation, and network/security verification. Run the program-wide punch list and coordinate witness assignments.

• as-tested code, configuration baselines, punch closure evidence, and commissioning records.

• Integrate with Quality’s validation system - protocols live in Quality’s framework and carry Quality’s approval; you author the automation content and align with Manufacturing Engineering’s master schedule and process acceptance criteria.

• Drive the integration and commissioning of robotics, vision systems, AGVs, conveyors, and motion control systems—including servos and VFDs—to enable seamless material flow and high reliability production operations.

• Configure and maintain communications between PLCs/HMIs and higher level systems (MES/SCADA). Develop and troubleshoot SCADA tags, transactions, alarming, and data acquisition as required.

• Serve as a senior-level escalation point for diagnosing complex automation issues involving networks, motion systems, instrumentation, and industrial communication protocols.

Deliverables You Will Develop, Review, or Support

• PLC code architecture, HMI screens, vision inspection programs, tag databases, MES/SCADA transaction lists, network IP lists, password inventories, and system backups. As-tested PLC code baselines, configuration backups, and acceptance evidence packages.

• Controls risk assessments, interlock/guarding logic, and safety rated PFMEA inputs.

• Controls layouts, network topology layouts, station cycle times, sequence diagrams, and automation simulations.

• Electrical schematics, pneumatic drawings, controls panel layouts, and industrial network architecture.

• FAT/SAT protocols, the program punch list, I/O checkout records, and handover packages.

Responsibilities and tasks outlined are not exhaustive and may change as determined by the needs of the business

Qualifications

• Bachelor’s or Master's degree in electrical engineering, Automation Engineering, Mechatronics, or related field with 7 + years of direct industrial automation and controls engineering experience .

• Strong hands-on experience programming and commissioning Siemens and Allen Bradley/Rockwell PLCs and HMIs.

• Demonstrated multi-vendor acceptance campaign management, disciplined change control with the ability to triage punch items to fix in situ or kick back to a vendor. Technical writing that vendors and auditors can both execute against.

• Deep understanding of servos, VFDs, highspeed conveyors, robotic cells, and automated material handling systems.

• Proficiency with Ethernet/IP, Profinet, EtherCAT, OPCUA, Modbus, serial, and similar industrial communication standards.

Must be a U.S. Person due to required access to U.S. export-controlled information or facilities

Preferred Skills

• Background as a commissioning-focused controls engineer at a system integrator or machine OEM - someone who has both written machine code and accepted other people’s.

• Robotics & Vision Systems: Working experience with multi axis robotic systems (Fanuc, Kuka, ABB) and machine vision platforms (Cognex, Keyence)

• Experience in heavy industrial, greenfield, chemical, or metallurgical manufacturing environments.

• Experience developing SCADA applications in Ignition, FactoryTalk, Wonderware, or similar platforms.

• AGV integration experience

• Familiarity with Python, C++, or other high-level languages for automation or data analytics.

• Experience in regulated industries or such as Defense, Aerospace, or Automotive or GAMP 5 / computer system validation exposure

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