Senior Controls Engineer - Helion : Job Details

We are seeking an experienced Senior Controls Engineer for a contract engagement within a manufacturing environment. The engineer will be responsible for two critical phases:

Study & Documentation Phase:

• Conduct a comprehensive technical assessment of an operational production line. This includes evaluating the control systems, PLC logic, HMI functionality, drives, safety systems, and network architecture. Deliverables include system documentation, improvement recommendations, and risk points.

Troubleshooting & Support Phase:

• Apply insights from the first line to troubleshoot and bring up an identical production line with existing operational issues. Collaborate with internal maintenance and engineering staff to diagnose root causes, optimize machine performance, and stabilize line operations.

Responsibilities:

• Review and reverse-engineer existing control system architecture (PLC, HMI, drives, sensors, etc.)
• Document ladder logic, I/O configurations, and control sequences
• Identify performance bottlenecks, failure modes, and opportunities for optimization
• Troubleshoot machine controls and automation issues on a mirrored production line
• Interface with production, maintenance, and engineering teams to implement fixes
• Provide a final technical report with observations, solutions, and recommendations

Qualifications:

• 10+ years of experience in controls/automation engineering
• Proficiency with Allen-Bradley/Rockwell Automation platforms (Logix 5000, FactoryTalk, etc.)
• Strong understanding of industrial networks (EtherNet/IP, DeviceNet, etc.)
• Ability to work independently in a fast-paced production environment
• Strong communication and documentation skills