Staff Automation Controls Engineer 

Job Title: Staff Automation Controls Engineer

Project Details
The Staff Automation Controls Engineer will support high-speed, automated medical device manufacturing systems at this TSG Client. This role is responsible for the architecture, development, integration, and optimization of PLC-based automation systems using Rockwell RSLogix 5000 / Studio 5000, advanced Cognex Designer Vision Systems, and industrial HMI platforms. The engineer will act as a senior technical lead, supporting new equipment builds, production upgrades, validation efforts, and continuous improvement initiatives in a regulated manufacturing environment.
The position involves cross-functional collaboration with Manufacturing, Quality, R&D, and external equipment vendors to improve yield, reliability, and equipment efficiency.

Daily Responsibilities:

PLC Programming & Controls Architecture (Rockwell – RSLogix 5000 / Studio 5000)

• Design, develop, and maintain modular PLC programs using Ladder Logic, Structured Text, and Function Block
• Architect scalable PLC code structures for high-speed automation systems
• Develop and optimize motion control logic for:
  • Servo motors
  • Robotics
  • Pneumatic actuators
• Configure and manage EtherNet/IP communications and I/O mapping
• Implement safety interlocks and machine protection systems
• Perform real-time troubleshooting on production equipment
• Conduct root cause analysis for downtime events
• Support FAT, SAT, commissioning, and validation protocols
• Review and mentor junior engineers on PLC coding standards

• Design and configure operator interfaces (PanelView / Ignition-based HMIs)
• Develop intuitive workflows for:
  • Machine start-up and shutdown
  • Recipe management
  • Alarm handling and fault recovery
• Create alarm management systems with prioritized fault logic
• Integrate HMI screens with PLC tag databases
• Develop real-time dashboards displaying:
  • Production metrics
  • Yield performance
  • Equipment status
• Implement role-based access controls in GMP environments
• Troubleshoot HMI-to-PLC communication issues

• Develop and deploy inspection programs using Cognex Designer
• Configure tools such as:
  • Pattern matching
  • OCR/OCV
  • Blob analysis
  • Precision measurement tools
• Integrate vision inspection outputs into PLC decision logic
• Calibrate and optimize camera and lighting systems
• Reduce false rejects and improve inspection reliability
• Validate vision systems for regulated manufacturing compliance

• Integrate PLC data into Ignition SCADA systems
• Support MES connectivity and production data logging
• Improve validation processes for software and equipment upgrades
• Identify opportunities to increase equipment yield and efficiency
• Evaluate and implement emerging automation technologies
• Apply machine learning techniques to optimize manufacturing performance (where applicable)

• Bachelor’s degree with 8+ years of related experience
• Strong expertise in:
  • Rockwell RSLogix 5000 / Studio 5000 PLC programming
  • High-speed automated manufacturing systems
  • Motion control (servo systems, robotics, pneumatics)
• Hands-on experience with Cognex Designer Vision Systems
• HMI development experience (PanelView and/or Ignition)
• Electrical troubleshooting experience in production environments
• Strong problem-solving and critical thinking abilities
• Experience working in regulated manufacturing environments (medical device preferred)

• Project management experience
• Ignition Gold Certification
• Experience implementing machine learning in manufacturing