Amerex- Manufacturing Technology Controls Engineer

Amerex•Trussville, AL

5d•Onsite

About The Position

Under the direction of the Automation & Equipment Manager, this position will be responsible for assisting in process improvements, equipment design, and project management associated with the various controls processes. Shall include, but not be limited to, the following: Develop, modify, and maintain PLC, HMI, and SCADA programs on the Rockwell Automation platform (Studio 5000, ControlLogix and CompactLogix, FactoryTalk View), following site standards for tag naming, routine structure, and documentation. Design, configure, and support industrial control networks including EtherNet/IP, device-level ring architectures, managed switches, and IP addressing schemes, in coordination with IT on OT network security and segmentation. Evaluate existing control systems, code, and network architecture; identify gaps in reliability, safety, maintainability, and performance; and design and implement improvements. Translate product and process requirements into control system specifications by studying equipment, assembly operations, and process flow on the floor with production, quality, and maintenance. Specify, procure, install, and commission controls hardware — drives, servos, sensors, instrumentation, vision systems, safety devices — including FAT, SAT, startup, and operator handoff. Collect and analyze production, downtime, and process data; quantify losses; and prepare reports and capital appropriation requests with ROI and payback analysis to justify machine improvements, process changes, and capital investment. Provide technical troubleshooting support for control system faults affecting production, including off-shift and on-call response for critical downtime. Design and validate machine safety circuits in compliance with OSHA, NFPA 79, and applicable ANSI/RIA and ISO standards; support lockout/tagout, guarding, and risk assessment. Maintain accurate controls documentation — electrical drawings, network diagrams, program backups, and revision control. Train maintenance technicians and operators on new and modified systems to build in-house troubleshooting capability. Manage integrators and vendors on assigned projects, including scope, schedule, and technical acceptance.

Requirements

Bachelor's degree in Electrical Engineering, Mechanical Engineering, Mechatronics, or a related technical field — or equivalent combination of technical education and hands-on controls experience.
3-5 years programming and troubleshooting PLCs in a manufacturing environment, with demonstrated Rockwell/Allen-Bradley proficiency.
Working knowledge of industrial networking protocols and troubleshooting.
Ability to read and interpret electrical schematics, P&IDs, and mechanical drawings.
Practical understanding of machine safety requirements and electrical safe work practices.
Willingness to support production during off-hours as needed.
Candidate needs to be a self-starter and able to work with minimal supervision.
Strong verbal and technical writing skills with the ability to communicate to broad audiences.
Proficient in Microsoft Office to include, Outlook, Excel, and Word, Autodesk Inventor or similar 3D modeling software.

Nice To Haves

Strong mechanical aptitudes a plus.
Knowledge of quality tools and continuous improvement methodologies a plus. (FMEA, Root Cause, 5S, Six Sigma, and Process Flow Analysis).
Experience with robotics (Fanuc) and machine vision systems.
VFD and servo configuration and tuning.
SQL, historian, or data analytics experience for production reporting.
Project management or capital project delivery experience.

Responsibilities

Develop, modify, and maintain PLC, HMI, and SCADA programs on the Rockwell Automation platform (Studio 5000, ControlLogix and CompactLogix, FactoryTalk View), following site standards for tag naming, routine structure, and documentation.
Design, configure, and support industrial control networks including EtherNet/IP, device-level ring architectures, managed switches, and IP addressing schemes, in coordination with IT on OT network security and segmentation.
Evaluate existing control systems, code, and network architecture; identify gaps in reliability, safety, maintainability, and performance; and design and implement improvements.
Translate product and process requirements into control system specifications by studying equipment, assembly operations, and process flow on the floor with production, quality, and maintenance.
Specify, procure, install, and commission controls hardware — drives, servos, sensors, instrumentation, vision systems, safety devices — including FAT, SAT, startup, and operator handoff.
Collect and analyze production, downtime, and process data; quantify losses; and prepare reports and capital appropriation requests with ROI and payback analysis to justify machine improvements, process changes, and capital investment.
Provide technical troubleshooting support for control system faults affecting production, including off-shift and on-call response for critical downtime.
Design and validate machine safety circuits in compliance with OSHA, NFPA 79, and applicable ANSI/RIA and ISO standards; support lockout/tagout, guarding, and risk assessment.
Maintain accurate controls documentation — electrical drawings, network diagrams, program backups, and revision control.
Train maintenance technicians and operators on new and modified systems to build in-house troubleshooting capability.
Manage integrators and vendors on assigned projects, including scope, schedule, and technical acceptance.