Process Automation Controls Engineer III

TekniPlex•Winston-Salem, NC

2d•$100,000 - $114,000•Onsite

About The Position

The Process Automation Controls Engineer owns the automation, controls, and plant-floor data systems that keep a multi-building manufacturing facility running. This role spans PLC and HMI programming, SCADA and data historian systems, the industrial network, and the servers that support them. The engineer supports daily production, drives reliability and OEE improvements, and leads controls upgrades from design through commissioning. It is a hands-on role for someone who is as comfortable with a laptop plugged into a PLC on the floor as with SQL queries and network switches.

Requirements

Five or more years of controls related experience
Strong PLC programming and troubleshooting skills in Rockwell Studio 5000 / RSLogix (ladder logic required; structured text a plus).
Experience developing HMI/SCADA applications (Ignition preferred; FactoryTalk View or similar acceptable).
Working knowledge of SQL databases and industrial communication protocols (EtherNet/IP, Modbus, OPC UA).
Ability to read and create electrical schematics and troubleshoot control panels, VFDs, and field I/O.
Solid networking fundamentals: IP addressing, subnets, VLANs, managed switches.
Willingness to support production outside normal hours when needed.

Nice To Haves

Ignition Core or Gold certification.
Experience with Kepware, FactoryTalk Transaction Manager, Wonderware, or Grafana.
Python or Jython scripting experience.
Experience with OEE systems, recipe management, or historian migrations.
Background in plastics, extrusion, or converting processes.
Exposure to Siemens TIA Portal, Omron, or other non-Rockwell platforms.
Familiarity with UniFi / Ubiquiti network and security products, VMware or Hyper-V, and Active Directory.

Responsibilities

Program, troubleshoot, and modify PLCs and HMIs across a mixed-vendor plant, primarily Rockwell/Allen-Bradley, with Siemens, Schneider/Modicon, Omron, AutomationDirect, and Unitronics equipment.
Support production equipment including extruders, laminators, presses, winders, and utility systems (HVAC, cooling tower, tank farm); respond to controls-related downtime.
Lead drive upgrades, retrofits, and machine revamps: scope, design, electrical schematics, panel changes, programming, and startup.
Read, create, and maintain electrical drawings, size power supplies, protection, and components.
Develop and maintain Ignition SCADA (Perspective and Vision) for HMI, OEE tracking, recipe management, and machine and utility monitoring.
Maintain data historian and database systems (PostgreSQL, Microsoft SQL Server), including tag historization, named queries, and audit logging.
Manage OPC and connectivity layers such as Kepware / TOP Server; support legacy FactoryTalk and Wonderware systems during migration.
Support production-monitoring platforms (e.g., Shoplogix) and plant display boards; build dashboards and reports for operations and process engineering.
Write and maintain scripts (Python/Jython, SQL) for automation, data handling, and reporting.
Administer the industrial/OT network: managed switches, VLANs, and device IP management, in coordination with corporate IT.
Maintain control-system servers and virtual machines, backups, software licensing, and Windows / Active Directory accounts for OT systems.
Support plant security systems such as badge access and camera systems (UniFi).
Identify and implement automation projects that improve uptime, quality, safety, and OEE.
Keep programs, network drawings, IP lists, credentials, and system documentation current and backed up.
Work closely with maintenance, process engineering, production, and IT; train technicians and operators on new systems.
Follow and promote plant safety practices, including LOTO, arc-flash, and machine guarding requirements.