Automation Controls Engineer
4 days ago
Phoenix
Job Description Job Title: Automation Controls Engineer Job Description The Automation Controls Engineer identifies and delivers automation and process improvement opportunities across manufacturing operations, with a clear annual goal of generating substantial cost savings through automation and continuous improvement. This hands-on role designs, programs, and supports control systems, robotics, and vision systems while leading capital automation projects from concept through production. The position requires a technically strong, curious, and accountable engineer who thinks and acts like an owner, drives measurable results, and partners closely with cross-functional teams to modernize operations and strengthen manufacturing capabilities. Responsibilities • Identify and evaluate areas within the manufacturing process that can be automated, focusing on productivity, quality, and cost savings targets such as the annual $800K improvement goal., • Design, program, and troubleshoot PLC-based control systems for manufacturing equipment and automated processes, including development of standardized control architectures and documentation., • Develop, integrate, and optimize industrial robotic applications, including programming and supporting robots such as Fanuc and similar platforms., • Design, implement, and maintain machine vision systems for inspection, validation, and process control, including Keyence and Cognex platforms or equivalent technologies., • Integrate sensors, motors, actuators, servo systems, safety circuits, and HMI interfaces into robust, reliable automated solutions., • Install, configure, and maintain a wide range of industrial sensors and automation devices, including SCHUNK sensors, SMC components, Banner sensors, proximity sensors, retroreflective sensors, fiber optic sensors, and light curtain sensors., • Perform diagnostics on sensors and related control systems to ensure proper functionality and high equipment uptime., • Design, update, and improve HMI screens to enhance operator usability, process visibility, and overall equipment effectiveness., • Lead root cause investigations for automated equipment failures using structured, data-driven problem-solving methods and implement sustainable corrective actions., • Develop automatic production and performance reports that support data-driven decision making and continuous improvement initiatives., • Partner closely with Manufacturing Engineering, Operations, Quality, Supply Chain, Test, Certification, and Purchasing to support new product introductions and automation projects., • Evaluate, recommend, and justify new automation technologies, robotics platforms, vision systems, smart sensors, and digital manufacturing tools, including determining return on investment., • Lead capital equipment and automation projects from concept through specification, vendor selection, budgeting, scheduling, installation, validation, and production handoff., • Drive continuous improvement initiatives that increase uptime, throughput, quality, and labor productivity, applying lean manufacturing and process improvement principles where appropriate., • Champion cybersecurity and controls best practices for industrial automation systems to maintain secure and reliable operations., • Provide technical mentorship, training, and support to maintenance and engineering teams on control systems, robotics, sensors, and new technologies., • Operate, program, and troubleshoot control systems using Studio 5000 software and related vision systems., • Read and interpret electrical schematics and control panel layouts, and use this knowledge to troubleshoot, optimize, and modify control systems., • Manage project performance by setting clear deadlines and budgets, participating in weekly progress reviews, and ensuring on-time and on-budget delivery of development and automation projects., • Continuously research emerging automation technologies, assess their business impact, and contribute to automation roadmaps aligned with operational and strategic objectives., • Pilot and implement advanced technologies such as AI-driven inspection, smart sensors, and digital manufacturing tools, while simplifying and standardizing control systems to reduce complexity and long-term maintenance., • Bachelor’s degree in Electrical Engineering, Mechatronics Engineering, Robotics Engineering, or a closely related field., • Minimum 3–5 years of experience in industrial controls and automation engineering., • Approximately 5 years of experience programming PLCs such as Allen-Bradley, Siemens, or equivalent platforms., • Approximately 5 years of hands-on experience integrating industrial robots such as Fanuc, ABB, KUKA, Universal Robots, or equivalent., • Approximately 5 years of experience implementing and troubleshooting machine vision systems, including Keyence and Cognex or similar platforms., • Approximately 5 years of experience with motion control systems, servo drives, and industrial networking technologies such as EtherNet/IP and Profinet., • Strong ability to read and interpret electrical schematics and control panel layouts, and apply this knowledge to troubleshooting and design., • Proficiency in designing, programming, and troubleshooting PLC-based control systems for manufacturing equipment and automated processes., • Experience identifying new areas to automate within manufacturing processes and translating findings into practical automation solutions., • Proven ability to manage capital equipment and automation projects, including schedule, budget, equipment selection, supplier coordination, and ROI determination., • Hands-on experience with vision system sensor selection, implementation, and integration into automated inspection or process control., • Strong troubleshooting skills for automation equipment, sensors, and control systems, including root cause analysis and corrective action., • Solid understanding of automation fundamentals, including sensors, schematics, control logic, and system optimization., • Experience with process improvement, continuous improvement, and lean manufacturing concepts applied to automated and manual processes., • Ability to operate, program, and troubleshoot systems using Studio 5000 software and associated vision platforms., • Demonstrated ownership and accountability, delivering measurable results and completing tasks and assignments on time., • Strong analytical and data-driven problem-solving skills applied to complex automation systems., • Experience managing automation-related capital projects, including justification, planning, and execution, is preferred., • Lean or Six Sigma experience is a plus and supports continuous improvement and waste reduction in automated processes., • Experience with fanuc robots or similar industrial robotic systems is highly valuable., • Experience in manufacturing engineering, automation, troubleshooting, programming, and sensor systems enhances success in this role., • Experience driving productivity improvements through equipment upgrades and process improvements., • Ability to develop and maintain standardized controls architectures and documentation that support scalability and reliability., • Demonstrated ability to act as a technical leader and subject matter expert in controls, robotics, and automation technologies., • Curious, self-driven mindset with a desire to figure things out, identify opportunities, and take ownership from concept through completion., • Comfort working in cross-functional teams that include engineering, test, certification, purchasing, quality, and operations., • Strong bias for action, with urgency and decisiveness in solving technical challenges and supporting production needs. This position operates in both office and manufacturing environments, with significant time spent on the production floor working directly with automated equipment, electrical panels, robotics systems, sensors, and vision equipment. The role uses standard office tools such as computers and communication systems, along with engineering and programming software including Studio 5000 and vision system interfaces. The facility designs, tests, and manufactures products on-site, providing close proximity to the full product lifecycle and a strong connection between engineering and operations. The organization offers a small-company culture with a close-knit team environment, while benefiting from the resources and stability of a larger parent company. The work culture emphasizes ownership, accountability, urgency, innovation, and teamwork, with regular project reviews and progress updates. Dress expectations align with a professional office and manufacturing setting, with appropriate attire and safety gear required when working on the production floor around automated equipment and electrical systems. Job Type & Location This is a Contract to Hire position based out of Phoenix, AZ. Pay and Benefits The pay range for this position is $45.67 - $57.69/hr. Eligibility requirements apply to some benefits and may depend on your job classification and length of employment. Benefits are subject to change and may be subject to specific elections, plan, or program terms. If eligible, the benefits available for this temporary role may include the following: • Medical, dental & vision, • Critical Illness, Accident, and Hospital, • 401(k) Retirement Plan – Pre-tax and Roth post-tax contributions available, • Life Insurance (Voluntary Life & AD&D for the employee and dependents), • Short and long-term disability, • Health Spending Account (HSA), • Transportation benefits, • Employee Assistance Program • Hiring diverse talent, • Maintaining an inclusive environment through persistent self-reflection, • Building a culture of care, engagement, and recognition with clear outcomes Our Bangalore, Hyderabad, Pune, and Chennai delivery centers are hubs of engineering expertise, with core capabilities in mechanical and electrical engineering, systems and software, and manufacturing engineering. Our teams deliver work across multiple industries including transportation, consumer and industrial products, and life sciences. We serve more than 4,500 clients, including many Fortune 500 brands. Learn more about how we can work together at actalentservices.com.