Senior Engineer – Warehouse Controls Engineer

Abbott • North Chicago, IL

23d • Onsite

About The Position

The Warehouse PLC / Controls Engineer is responsible for maintaining, troubleshooting, and improving automated control systems within a warehouse or distribution environment. This role focuses on maximizing system uptime through rapid issue resolution, preventive maintenance, and continuous improvement of PLC-controlled equipment such as conveyors, sortation systems, and automated material handling systems.

Diagnose and resolve Programmable Logic Control (PLC), Human machine interface (HMI), and control system issues impacting warehouse operations. Provide real-time support to operations teams to minimize downtime. Analyze system faults, alarms, and logs to identify root causes and implement corrective actions. Support troubleshooting of automation systems including conveyors, sorters, pick by light and robotics systems.

System Documentation
Develop and maintain accurate as-built documentation for PLC programs, network architecture, and control systems. Update electrical schematics, I/O lists, and system configurations as modifications occur. Ensure documentation is organized, version-controlled, and easily accessible.

Troubleshooting Guides & Knowledge Sharing
Create and continuously improve standardized troubleshooting guides and procedures. Develop training materials and provide guidance to operators and maintenance technicians. Capture lessons learned from recurring issues to build robust knowledge bases.

Continuous Improvement & Upgrades
Identify opportunities for system improvements to enhance reliability, efficiency, and performance. Propose and implement equipment upgrades, control logic enhancements, and process optimizations. Collaborate with vendors and engineering teams on system modifications and new installations.

Preventive & Predictive Maintenance
Develop and execute preventive maintenance strategies for PLCs, control panels, and automation systems. Monitor system health and implement predictive maintenance techniques to prevent failures. Ensure compliance with maintenance schedules to maximize uptime and equipment lifespan.

Testing & Commissioning
Support commissioning of new equipment, system upgrades, and retrofit projects. Conduct Factory and site acceptance testing (FAT/SAT) testing and validate system performance post-implementation. Verify proper operation of safety circuits and compliance with standards.

Requirements

• Bachelor’s degree in engineering (Electrical or Controls Engineering preferred) or equivalent work experience.
• 4-7+ years of experience with PLC programming and troubleshooting (Prefer Allen-Bradley).
• FDA regulated manufacturing, consumer packaged goods or similar experience.
• Experience with validation or commissioning documentation.
• PLCs(Programmable Logic Control), HMIs(Human machine interface), VFDs (Variable Frequency Drive), and industrial networks (EtherNet/IP, Profibus, etc.)
• Electrical systems and control panels
• Proven ability to troubleshoot complex automation issues under time pressure.

Nice To Haves

• Warehouse automation, distribution centers, or material handling systems.
• Experience with WMS (Warehouse Management Systems) and other IT/OT systems integration.
• Working knowledge of the principles of quality software engineering as described by software lifecycle development processes that are consistent with ISO, IEEE, or other FDA recognized standards.
• Programming experience using current programming languages (C#, html, SQL) and/or experience in software development.
• Be familiar with tools within Continuous Improvement (e.g., 6 Sigma, Lean, Kaizen, etc.) and participate in problem resolution.
• Ability to manage multiple tasks and know how to prioritize the workday.
• ‘Out-of-the-box’ thinking and problem solving.

Responsibilities

• Diagnose and resolve Programmable Logic Control (PLC), Human machine interface (HMI), and control system issues impacting warehouse operations.
• Provide real-time support to operations teams to minimize downtime.
• Analyze system faults, alarms, and logs to identify root causes and implement corrective actions.
• Support troubleshooting of automation systems including conveyors, sorters, pick by light and robotics systems.
• Develop and maintain accurate as-built documentation for PLC programs, network architecture, and control systems.
• Update electrical schematics, I/O lists, and system configurations as modifications occur.
• Ensure documentation is organized, version-controlled, and easily accessible.
• Create and continuously improve standardized troubleshooting guides and procedures.
• Develop training materials and provide guidance to operators and maintenance technicians.
• Capture lessons learned from recurring issues to build robust knowledge bases.
• Identify opportunities for system improvements to enhance reliability, efficiency, and performance.
• Propose and implement equipment upgrades, control logic enhancements, and process optimizations.
• Collaborate with vendors and engineering teams on system modifications and new installations.
• Develop and execute preventive maintenance strategies for PLCs, control panels, and automation systems.
• Monitor system health and implement predictive maintenance techniques to prevent failures.
• Ensure compliance with maintenance schedules to maximize uptime and equipment lifespan.
• Support commissioning of new equipment, system upgrades, and retrofit projects.
• Conduct Factory and site acceptance testing (FAT/SAT) testing and validate system performance post-implementation.
• Verify proper operation of safety circuits and compliance with standards.

Benefits

• Employees can qualify for free medical coverage in our Health Investment Plan (HIP) PPO medical plan in the next calendar year.
• An excellent retirement savings plan with high employer contribution
• Tuition reimbursement, the Freedom 2 Save student debt program and FreeU education benefit - an affordable and convenient path to getting a bachelor’s degree.

What This Job Offers

• Job Type: Full-time
• Career Level: Senior