Maintenance Technician (Controls Specialist)

Cornerstone Building Brands•Rocky Mount, VA

10h•Onsite

About The Position

The Sr. Maintenance Controls Specialist is a senior-level electro-mechanical and industrial automation position responsible for the reliability, maintenance, troubleshooting, design, modernization, and implementation of manufacturing equipment control systems. This role serves as the facility's primary technical resource for automation, controls, and machine integration while also maintaining strong hands-on mechanical troubleshooting and repair capabilities. The Sr. Maintenance Controls Specialist is responsible for supporting manufacturing operations through advanced diagnostics, PLC/HMI programming, electrical troubleshooting, machine reliability improvements, and controls modernization projects. This position is expected to independently evaluate aging and obsolete equipment, develop replacement control system specifications, create project scopes and budgets, implement control system upgrades, and commission new systems with minimal reliance on outside contractors. The individual must possess strong electrical, automation, and mechanical skills and be capable of working independently on complete machine systems when additional technical resources are not available.

Requirements

Associate degree in Electrical Engineering Technology, Mechatronics, Industrial Automation, Controls Technology, or related field preferred; equivalent experience considered.
Minimum 7–10 years of industrial maintenance, automation, controls, or related manufacturing experience.
Demonstrated ability to independently troubleshoot, modify, and develop PLC programs.
Demonstrated ability to commission and support industrial automation systems.
Advanced knowledge of industrial electrical systems and motor controls.
Strong mechanical troubleshooting skills including pneumatics, hydraulics, conveyors, bearings, drives, and machine alignment.
Ability to work independently with minimal supervision on both controls and mechanical issues.
Experience with Allen-Bradley ControlLogix, CompactLogix, PLC-5, SLC-500, and MicroLogix preferred.
Experience with Siemens, Omron, Mitsubishi, Modicon, GE, and legacy PLC platforms preferred.
Must be at least 18 years of age to apply.

Nice To Haves

Experience with Allen-Bradley ControlLogix, CompactLogix, PLC-5, SLC-500, and MicroLogix preferred.
Experience with Siemens, Omron, Mitsubishi, Modicon, GE, and legacy PLC platforms preferred.

Responsibilities

Diagnose and repair complex automation and control system failures on manufacturing equipment.
Read, interpret, troubleshoot, modify, document, and develop PLC programs across multiple platforms and generations of technology.
Develop new PLC logic, HMI applications, recipes, and machine control strategies.
Troubleshoot and repair electrical control circuits, sensors, encoders, photo eyes, safety devices, VFDs, soft starters, servo systems, motion control systems, and industrial networks.
Commission and start up new or modified automation systems.
Create, maintain, and update electrical schematics, control drawings, panel layouts, and documentation.
Maintain backups of PLC, HMI, drive, servo, and robot programs.
Train maintenance and operations personnel on control systems.
Evaluate obsolete control systems and develop long-term modernization strategies.
Maintain a controls obsolescence roadmap and prioritize modernization efforts.
Research and specify replacement PLCs, HMIs, drives, instrumentation, communication systems, and electrical hardware.
Develop project scopes, bills of materials, cost estimates, and technical specifications.
Lead controls retrofit and modernization projects from concept through startup.
Design, install, configure, program, test, and commission replacement control systems with minimal outside contractor support.
Manage contractors, vendors, and system integrators when utilized.
Diagnose and repair complex electro-mechanical problems.
Perform setup, calibration, and adjustment of equipment.
Troubleshoot and repair pneumatic, hydraulic, electrical, and mechanical systems.
Perform preventive, predictive, and corrective maintenance.
Perform root cause failure analysis and develop permanent corrective actions.
Implement reliability improvements that reduce downtime.
Enter completed work and documentation into the CMMS system.
Serve as the facility primary technical expert for automation and controls systems.
Mentor and train maintenance technicians.
Provide technical guidance during equipment failures, startups, and major maintenance events.
Support continuous improvement initiatives.
Perform other duties as assigned.