Controls & Automation Engineer
Location: Hammond, IN
Employment Type: Full-Time | Direct Hire
Salary Range: $120,000–$130,000 annually (base)
Shift: 6:00 AM – 4:00 PM (schedule flexibility required)
No visa transfers or sponsorship available
No OPT/CPT/F1 visas please
Job Summary
The Controls & Automation Engineer is responsible for maintaining, troubleshooting, and improving automated manufacturing systems. This role partners closely with cross-functional teams to ensure the reliable and optimal performance of robotic, PLC, and automation equipment across multiple shifts.
Key Responsibilities
- Provide automation and controls support for manufacturing operations across all shifts
- Integrate, program, troubleshoot, repair, and maintain Fanuc and Universal Robots (UR) robotic systems
- Manage small automation projects including robotic integrations, safety upgrades, and equipment retrofits
- Perform advanced electrical and mechanical troubleshooting on automated equipment
- Program and support Allen-Bradley PLCs (MicroLogix, CompactLogix, ControlLogix) using RSLogix 500, RSLogix 5000, and Studio 5000
- Read and interpret electrical schematics and prints to diagnose and restore down equipment
- Design electrical panels, layouts, wiring schematics, and bills of material (BOM)
- Define control system requirements and develop automation design criteria based on engineering analysis
- Design automation and control systems from field devices through PLC and SCADA platforms
- Develop, test, and implement PLC and SCADA applications for manufacturing processes and equipment
- Ensure all automation designs comply with applicable regulations and standards (OSHA, NEC, NFPA, GMP)
- Analyze system performance data to identify issues and implement effective solutions
Required Qualifications
- Bachelor’s degree in Electrical Engineering, Mechanical Engineering, Automation, or related field
- 5+ years of experience in automation engineering or industrial controls
- Hands-on experience with:
- Allen-Bradley PLC programming
- Robotics programming (Fanuc preferred)
- SCADA systems and HMI development
- Proficiency in Ladder Logic and Structured Text programming
- Strong problem-solving and analytical skills
- Ability to work independently and collaboratively in a team environment
Preferred Skills and Experience
- Fanuc robot programming and Fanuc 3DV vision systems
- Robot-guided vision systems and offset management
- FactoryTalk HMI, Balluff IO-Link, and Ignition or similar SCADA platforms
- AutoCAD electrical design experience
- Knowledge of machine safety standards (OSHA 1910, ANSI/RIA 15.06, conveyor and robotic safety)
- Experience with Automated Guided Vehicles (AGV/AMR)
- MES system integration and external manufacturing system communication
- Atlas Copco ToolsTalk programming and torque tool integration
- Automation risk assessment development and completion
- Working knowledge of Microsoft Office applications
Special Requirements
- Willingness to work extended hours, variable shifts, weekends, and holidays as needed
- Ability to be on-call and respond immediately to critical equipment or process issues
Knowledge, Skills, and Abilities
- Strong knowledge of regulatory codes and standards including GMP, OSHA, NEC, and NFPA
- Understanding of Distributed Control Systems (DCS) programming
- Solid electrical engineering fundamentals, including system interactions and equipment sizing
- Experience configuring and supporting HMI and SCADA systems