Engineer, Senior Controls

The Sr. Controls Engineer position is in our Carrollton, TX facility. This is not a remote role.

Position Summary:  The Sr. Controls Engineer works directly with 4Front product teams, mechanical suppliers, direct customers, and/or customer service.  This role is responsible for planning, designing, and implementing control systems, communication networks, and advanced computer applications.  Will frequently conduct ground level programming, new machine installation, upgrades, and troubleshooting for various programs, industrial robotics, and production systems.  This role will work with a large variety of equipment and technical systems, including, but not limited to; PLC systems, production robots, Servo systems, and SCADA systems. This role will also direct and educate electricians and other potential personnel to assist and operate in the same areas of programming and troubleshooting.  Will be required to work independently on engineering tasks as well across teams and assist in new business development. 

The Sr. Controls Engineer may be assigned as a project leader to develop, design, and implement process improvement projects throughout the facility. This position will manage designated engineering projects and oversee all aspects of equipment and process improvements involving conceptualization, tracking cost, development, production implementation, and post-launch support within respective teams. This position will also conduct training among manufacturing personnel to ensure proper usage of processes and equipment. This position relies on strong communication and interpersonal skills to provide direction, assistance, training, and understanding of plant processes and systems to internal personnel and contractors. 

1. Description of Essential Job Functions: 

1. Operations 

1. Develop SCADA system master plans, performing needs assessments and providing innovative solutions involving SCADA systems, instrumentation, communication networks, radio and cellular communication systems and cyber security practices. 

2. Develop plans and/or drawings including SCADA system architectures, control panels layout, loop diagrams, process control descriptions and procedures. 

3. Support production by performing small to large project troubleshooting and programming services of existing and new plant automation equipment including PLC, HMI, and reporting software programming of multiple vendors. 

4. Complete programming of robots and touching up points as needed to support production needs. 

5. Work with production and process to optimize line flow, cycle time issues, and quality concerns through changes in programming or troubleshooting of controls. 

6. Work to help develop new technology for the plant to utilize in efforts to improve cycle times and quality detection/prevention systems.  

7. Help train plant technicians and engineers on controls related skills. 

8. Help plan preventative maintenance plans for equipment in the plant both new and current. 

9. Create and correct plant electrical drawings for equipment. 

10. Assist with the development of business process necessary to support growth in “Direct” sales channel of 4Front products. 

11. Work with plant teams to help develop accurate quoting models. 

2. Project Management 

1. Manage technical engineering projects, with an emphasis on the launch of new products and process improvements into current production operations. 

2. Oversee all aspects of equipment and process improvements involving conceptualization, tracking cost, development, production implementation, and post-launch support in a cross-functional team environment.  

3. Travel to equipment suppliers for equipment runoff and/or validations that pertain to the specific project he/she is responsible for, as necessary. 

4. Provide requirement gathering, design configuration, integration, and implementation of numerous process control solutions, including, but not limited to, batch software, AB PLC Logix series systems, HMI packages, SCADA systems, Visual Basic, PC networking technology, AC/DC motor drive systems, servo motor systems, routing systems, and robot controls and instrumentation. 

5. Contribute to the development and improvement of plant system processes and structures for acquiring, displaying, and trending process data. 

6. Collaborate with professional services providing subject matter expertise for proposal development. 

7. Review and interpret control system, construction, and installation drawings and the development of control system descriptions and training manuals. 

8. Troubleshoot automation systems as needed. 

9. Interact with contractors, maintenance, and production personnel to identify issues in plant processes and provide solutions. 

10. Provide direction, assistance, and training to maintenance electricians and plan and coordinate detailed aspects of engineering work. 

2. Supervisory Responsibilities: 

• This job has no supervisory responsibilities.  

3. Qualification Requirements: To perform this job successfully, an individual must be able to perform each essential duty satisfactorily. The requirements listed below are representative of the knowledge, skill, and/or ability required. Reasonable accommodations may be made to enable individuals with disabilities to perform the essential functions.  

Education and Experience: 

• Bachelor’s degree in Electrical Engineering, Electrical Technology, Mechanical Engineering, and/or other Engineering-related degree. 

• 5-10+ years of engineering experience, preferably in industrial controls with a strong background within a manufacturing environment. 

• 3–5 years of experience programming and troubleshooting PLCs and/or Robots. 

• 1-3 years of  knowledge/experience with Variable Frequency Drives (VFDs). 

• Experience with Gear Motor and Direct Drive Motors. 

• Experience with multiple HMI vendors, SCADA communication system. 

• Experience and demonstrated success managing multiple simultaneous assignments/projects and meeting schedules/timelines. 

• Significant “hands on the product” type experience with ability to recognize problems, predict potential outcomes, and implement countermeasures quickly enough to avoid problems. 

Computer Skills 

• Ability to use a personal computer utilizing spreadsheet and word processing software applications, databases, and automated systems to accomplish work. 

• Advanced/Intermediate skill level with Microsoft Office Suite; Word, Excel, Project, and PowerPoint preferred. 

• Ability to look up orders and navigate JDE. 

• Proficiency with AutoCAD. 

• Experience with Autodesk Inventor a plus. 

• Proficiency with MODBUS RTU. 

• Proficiency with BACnet protocol is a plus. 

• Understanding of LonWorks protocol a plus. 

• Demonstrated understanding of Cognex In-Sight software. 

• Ability to connect to PLC and navigate programming software. 

• Ability to use RS Net Worx software, RS View Studio, and Panel Builder software. 

• Understanding of basic concepts of MMIs; familiar with PanelView Plus and PanelView hardware. 

• Demonstrated understanding of Ethernet cabling and addressing, Device Net, RIO, and wireless PC networking. 

• Demonstrated knowledge of ladder logic programming, PLC 5, SLC500, ControlLogix, MicroLogix, RIO, Ethernet I/P, DeviceNet. 

Certificates, Certifications, Licenses, Registrations: 

• Professional engineering licensure is preferred. 

Other Skills, Abilities, or Competencies: 

• Excellent analytical skills. 

• Effective time management skills. 

• Ability to lead an engineering project. 

• Ability to read job plans and specifications. 

• Advanced/Hands on approach to problem solving and analysis. 

• Ability to design, diagnose, and troubleshoot vision applications. 

• Customer service orientation and approach to daily responsibilities.  

• Ability to function as a team member and contribute to group goals.  

• Ability to perform electrical troubleshooting and read electrical prints. 

• Demonstrated understanding of AC and DC motors and servo systems. 

• High level of understanding of Fanuc Robots and ABB robot operations. 

• Working knowledge of Mitsubishi, Schneider Electric, and Lenze drives. 

• The ability to develop, coordinate, and manage multiple concurrent projects. 

• Exceptionally high degree of self-checking, quality control, and attention to detail. 

• Ability to communicate clearly to departments within the company and outside customers. 

• Detail oriented with the ability to track and monitor projects from inception to completion. 

• Maintain accurate and consistent schedules for projects and tasks for multiple plant projects. 

• Efficiently capable of instrumentation, calibration, and troubleshooting of instrumented systems. 

• Effective construction, start-up, and commissioning techniques of control and instrumented systems. 

• Ability to develop and communicate technical information from various sources to implement designs. 

• Proven knowledge of PLC concepts and the application of these concepts to meet process applications. 

• Ability to organize personal workload, prioritize activities, and accomplish tasks under deadline pressure. 

• Ability to wire industrial control systems including 480V/120V/24V power, drives, motors, I/O and sensors. 

• Excellent electrical and mechanical aptitude/troubleshooting skills, and the ability to read engineering drawings. 

• Ability to work with a variety of technical skill sets to troubleshoot; identifying and correcting an issue by phone. 

• Strong written and oral communication skills to communicate with managers, fellow employees, customers, and vendors. 

• Expertise with various hardware equipment such as Allen Bradley, Siemens, and SCADA platforms (Pro-face, Red Lion, RSView, and WonderWare). 

• Familiarity with electrical power and distribution systems, SCR controllers, NEC codes, electrical installations, and panel building. 

• Ability to solve problems and deal with a variety of concrete variables in situations where only limited standardizations exist. 

• Maintain thorough knowledge and understanding of each customer’s specifications, standards, and other engineering requirements. 

• Requires ability to work cross functionally with Entrematic Technical Support Management to maintain business process consistency and control. 

• Ability to work in a group setting and independently while multi-tasking and adjusting to changing priorities in a minimally supervised fast paced environment. 

• Requires independent judgment and discretion with project framework for planning, organization, control, integration and completion of projects and company objectives. 

• General understanding and working knowledge of manufacturing, assembly, sewing, and welding equipment and tooling including design, gauges, equipment design, automation, robotics, or manufacturing processes. 

• Working knowledge of material types specifications and characteristics used in dock levelers, dock seals & shelters, impactable dock doors, high speed and high performance doors, and other entrance automation products and warehouse solutions. 

• Thorough understanding of company product, trade terminology, quality management and control systems and techniques, manufacturing processes including material controls, work flow, scheduling, just-in-time/pull system, machine operation, and company policies as standards. 

Other Qualifications, Experience, or Requirements: 

• Limited business travel in the field for project implementation, training, field testing, and/or customer support. 

• Requires a valid motor vehicle operator’s license and the ability to operate a motor vehicle while carefully observing all traffic rules and regulations. 

• Requires the ability to use a variety of office/production related equipment such as a telephone, photocopier, facsimile machine, and precision measuring instruments. 

• Work beyond the traditional 40 hours per week may be required as workload or projects dictate, including weekends and holidays. 

We are the ASSA ABLOY Group
Our people have made us the global leader in access solutions. In return, we open doors for them wherever they go. With nearly 61,000 colleagues in more than 70 different countries, we help billions of people experience a more open world. Our innovations make all sorts of spaces – physical and virtual – safer, more secure, and easier to access. 

As an employer, we value results – not titles, or backgrounds. We empower our people to build their career around their aspirations and our ambitions – supporting them with regular feedback, training, and development opportunities. Our colleagues think broadly about where they can make the most impact, and we encourage them to grow their role locally, regionally, or even internationally.

As we welcome new people on board, it’s important to us to have diverse, inclusive teams, and we value different perspectives and experiences.