seeking an experienced
Lead Controls Engineer to support industrial automation, plant-floor controls, and manufacturing operations at its Holcomb, Kansas facility.
The ideal candidate will have strong hands-on experience with PLC programming and troubleshooting, particularly Schneider Electric/Modicon systems. This role involves supporting automated production lines, conveyors, material-handling equipment, SCADA/HMI systems, industrial scanning devices, and plant-floor communication networks.
The engineer will troubleshoot complex control-system issues, identify root causes, support legacy equipment, and contribute to controls upgrades and modernization initiatives. The position also requires technical leadership, cross-functional collaboration, and ensuring reliable plant operations.
Key Responsibilities
- Lead troubleshooting, programming, commissioning, and maintenance of PLC-based industrial control systems.
- Diagnose and resolve issues involving Schneider Electric/Modicon PLCs, ladder logic, structured programming, and I/O mapping.
- Troubleshoot automated production equipment, conveyors, motors, drives, sensors, photo eyes, interlocks, and sequencing systems.
- Support and troubleshoot HMI/SCADA platforms, particularly Ignition and iFix.
- Integrate and troubleshoot industrial barcode scanners, vision systems, and identification equipment, including Keyence, Cognex, and SICK.
- Diagnose communication issues between PLCs, HMIs, scanners, field devices, and plant-floor systems.
- Interpret electrical schematics and trace faults across electrical, controls, communication, and equipment systems.
- Support both legacy and modern automation systems, including upgrades, replacements, and modernization projects.
- Develop, review, and modify control-system specifications, configurations, and programs.
- Develop and execute integrated test plans to verify system functionality and reliability.
- Follow established engineering standards, system development lifecycle methodologies, and plant procedures.
- Provide technical direction and recommendations to engineering teams, vendors, and management.
- Collaborate with cross-functional teams to improve equipment reliability, minimize downtime, and maintain production efficiency.
Required Qualifications
- Bachelor's degree in Computer Science, Information Systems, Engineering, or another technical field; equivalent experience may be considered.
- At least 6 years of experience in Information Systems, industrial controls, automation, or a related technical field.
- Proven programming and troubleshooting experience in industrial control environments.
- Strong hands-on PLC programming, commissioning, and troubleshooting skills.
- Experience with ladder logic, structured programming, I/O mapping, and HMI integration.
- Ability to read and interpret electrical schematics.
- Strong understanding of SCADA systems, scripting, server-based technologies, SQL, and industrial control applications.
- Experience with system development lifecycle methodologies, system testing, and technical documentation.
- Excellent problem-solving, communication, and cross-functional collaboration skills.
- Ability to communicate technical information effectively to technical and non-technical stakeholders.
Preferred Technical Skills
- PLC/Controls: Schneider Electric/Modicon PLCs, ladder logic, structured programming, and troubleshooting.
- Plant Automation: Automated production systems and manufacturing equipment.
- Conveyance Systems: Conveyors, motors, drives, sensors, photo eyes, interlocks, and sequencing.
- SCADA/HMI: Ignition and iFix.
- Industrial Scanning/Vision: Keyence, Cognex, and SICK systems.
- Industrial Communications: Troubleshooting communication between PLCs, HMIs, scanners, and field devices.
- Controls Modernization: Legacy equipment support, system upgrades, and replacements.
- Programming & Data: SQL, scripting, server-based systems, and 4GL programming.
