Lead Engineer, Controls - Gallman Consulting : Job Details

TITLE

Controls Supervisor

LOCATION

Decatur, AL

POSITION SUMMARY

The Controls Leader will provide key leadership regarding power and control systems, equipment specification, maintenance, proper operation, technician development, troubleshooting, and repair to achieve or exceed reliability targets at the plant. This role is responsible for systems optimization, compliance, personnel safety, and technician skill development related to plant electrical power and process control systems.

KEY RESPONSIBILITIES

• Assist the primary administrator and troubleshooter for plant power and control systems; serve as a key member of plant technical leadership.
• Provide input to the Engineering Projects Manager to develop and manage power and control standards, ensuring their application on all projects and upgrades.
• Lead the execution of the site master plan for power and control systems, including understanding the installed base and planning for obsolete equipment/technologies replacement.
• Build and maintain a sustainable system for plant Electrical & Instrumentation (E&I) technician skill development, coaching technicians on skill assessment and development.
• Manage Electrical & Instrumentation (E&I) technicians and set daily direction.
• Ensure technician compliance with local and national regulator codes (NFPA 70, NFPA 70e, NFPA 79, OSHA 1910) and ensure equipment and safe practice compliance within their area.
• Validate MES data from PLCs and support plant Process Engineers in conditioning PLC data for effective analysis, including application development.
• Support the design and implementation of machine control and process automation applications, such as control strategies, HMI design, MES applications, and KPI development.
• Collaborate with engineering and operations to identify losses and develop strategies to eliminate them in safety, quality, reliability, and cost areas.
• Own parts or whole key system elements related to power and control, including electrical safety (LOTO, PPE, energized work permits, low voltage qualification) and quality/CCP compliance (checkweighers, metal detectors, vision systems, ingredient flows, temperatures).
• Work closely with engineering and operations leaders on the selection, installation, and startup of new equipment, becoming the technical expert and ensuring proper training.
• Provide power and controls engineering support for capital initiatives.
• Offer daily support to other plant areas as needed.
• Learn and apply control, simulation, and process modeling technologies to analyze and improve operations.

SELECTION CRITERIA

Education

• Bachelor's Degree in Engineering is required; Electrical Engineering preferred.

Experience

• Minimum of 5 years of relevant controls experience required.
• Manufacturing experience preferred.
• Mechanical and electrical experience in food manufacturing preferred.

Other

• Ability to work and manage within a team environment.
• Strong knowledge of machine and process control hardware, instrumentation, and software, including Allen Bradley PLC and Rockwell FactoryTalk platforms.
• Working knowledge of NFPA and OSHA guidelines related to electrical equipment and practices.
• Proficiency in plant historian systems.
• Understanding of technical systems and terminology.
• Experience in learning and integrating new technologies.
• Experience leading the installation of equipment in a food manufacturing environment.
• Proven results in manufacturing maintenance utilizing maintenance systems.
• Experience with plant systems software.
• Self-motivated with the ability to motivate others.
• Strong organizational, critical thinking, and problem-solving skills.
• Effective presentation, verbal, and written communication skills.
• Proficient in Microsoft Suite applications.
• Excellent interpersonal skills.
• Willingness to work off-shifts or weekends as needed, including taking support calls.
• Experience in leading, teaching, or managing others effectively.
• Some travel required.
• Able to perform moderate physical activity, including significant time on the manufacturing floor and equipment work.

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