Controls Engineer

Location: N. Charleston, South Carolina

The Controls Engineer is responsible for the design, programming, commissioning, troubleshooting, and continuous improvement of industrial automation and electrical control systems supporting a high-volume manufacturing operation. This role serves as the plant's primary technical resource for PLC-based automation, HMI development, instrumentation, industrial networking, and electrical controls while partnering closely with Operations, Maintenance, and Engineering to improve equipment reliability, safety, quality, and productivity. Reporting to the Electrical Engineering Supervisor, the Controls Engineer supports capital projects, leads controls-related system upgrades, develops standardized automation solutions, and provides technical expertise during equipment failures and commissioning activities.

Job Responsibilities:

Controls & Automation

• Design, program, test, and commission PLC- and HMI-based control systems for new and existing manufacturing equipment.
• Develop, modify, and troubleshoot PLC logic, HMI applications, instrumentation, and industrial control systems.
• Configure and support variable frequency drives (VFDs), servo systems, industrial sensors, safety devices, and process instrumentation.
• Support industrial communication networks including EtherNet/IP, Profinet, Modbus, or similar industrial protocols. · Optimize automation systems to improve equipment uptime, process consistency, throughput, and product quality.
• Develop and maintain plant standards for PLC programming, HMI development, controls documentation, and electrical design.

Electrical Engineering

• Design and revise electrical schematics, control panel layouts, wiring diagrams, and bills of material using AutoCAD Electrical, EPLAN, or similar software.
• Specify electrical components and controls hardware for capital projects and equipment upgrades.
• Support electrical power distribution, motor control circuits, and machine control systems.

Manufacturing Support

• Serve as the primary engineering resource for troubleshooting complex electrical and automation issues affecting production equipment.
• Lead root cause analysis of recurring electrical and controls failures and implement permanent corrective actions.
• Work closely with Maintenance and Operations to minimize downtime and improve equipment reliability.
• Provide technical support during equipment startups, shutdowns, commissioning, and emergency production situations.

Capital Projects

• Support capital projects from concept through commissioning, including equipment specification, controls design, programming, factory acceptance testing (FAT), site acceptance testing (SAT), startup, and validation.
• Coordinate with OEMs, contractors, and system integrators during equipment installations and controls upgrades.
• Develop project schedules, technical specifications, procurement documentation, and project budgets as assigned.

Safety & Compliance

• Participate in Process Safety Management (PSM) activities, including Process Hazard Analyses (PHAs) and Pre-Startup Safety Reviews (PSSRs).
• Ensure compliance with OSHA, NEC, NFPA 70E, and internal electrical safety standards.
• Support lockout/tagout, machine safety, arc-flash mitigation, and safe electrical work practices.

Documentation & Continuous Improvement

• Maintain accurate PLC backups, electrical drawings, control narratives, and technical documentation.
• Identify opportunities to improve automation, reduce downtime, standardize controls hardware, and enhance manufacturing performance.
• Support Lean Manufacturing, reliability initiatives, and continuous improvement projects.

Minimum Qualifications:

• Bachelor's degree in Electrical Engineering, Electrical Engineering Technology, Controls Engineering, or a closely related discipline.
• 3-5 years of experience in industrial controls, automation, or electrical engineering within a manufacturing environment.
• Strong experience programming and troubleshooting PLCs and HMIs (Allen-Bradley ControlLogix/CompactLogix with Studio 5000 preferred).
• Experience with industrial automation systems, instrumentation, VFDs, motor controls, and industrial networking.
• Ability to read, create, and modify electrical schematics, wiring diagrams, and controls documentation.
• Experience troubleshooting complex automated manufacturing equipment in a production environment.
• Strong analytical, problem-solving, communication, and project management skills.
• Experience in a Process Safety Management (PSM) environment is preferred.

Preferred Qualifications

• Experience with Siemens PLC platforms.
• Experience with machine vision systems, servo motion control, robotics, and safety PLCs.
• Experience commissioning automated manufacturing equipment.
• Familiarity with SCADA systems and industrial data collection.
• Experience supporting capital projects in excess of $100,000.
• Lean Manufacturing, Six Sigma, TPM, or Reliability Engineering experience.

Protective Industrial Products (PIP) is an equal opportunity employer that is committed to diversity and inclusion in the workplace. We prohibit discrimination and harassment of any kind based on race, color, sex, religion, sexual orientation, national origin, disability, genetic information, pregnancy, or any other protected characteristic as outlined by federal, state, or local laws.

At PIP Global Safety, we are committed to fostering a diverse and inclusive workplace where all individuals are respected and valued. We do not tolerate discrimination or harassment of any kind, and we strive to ensure that employment decisions are based on qualifications, merit, and business needs. Employment practices and policies may be subject to variation based on applicable laws and regulations in different countries and jurisdictions.

This commitment applies to all aspects of employment, including hiring, recruiting, promotion, termination, compensation, benefits, training, and development opportunities. We believe that a diverse team strengthens our global success and enriches our culture