Controls Engineer
About the RoleAPEL Extrusions Inc. is seeking a hands-on Controls Engineer to support, maintain, troubleshoot, and improve automation and electrical control systems across its aluminum extrusion manufacturing operations. This plant-based position plays a critical role in equipment reliability, downtime reduction, automation improvements, and manufacturing systems integration.The Controls Engineer will work closely with Operations, Maintenance, Engineering, IT, contractors, and OEMs to diagnose complex equipment issues and lead automation projects from concept through commissioning. The role requires strong experience with PLCs, HMIs, drives, SCADA, SQL, industrial networking, and manufacturing systems, along with a willingness to work directly on the production floor.Key ResponsibilitiesDesign, program, troubleshoot, modify, and maintain Allen-Bradley ControlLogix and CompactLogix PLC systems.Program and troubleshoot Allen-Bradley PowerFlex variable frequency drives, PanelView HMIs, servo systems, motion controls, and related automation equipment.Modify PLC and HMI programs to improve equipment reliability, functionality, and performance.Implement machine safety logic, interlocks, and control strategies.Diagnose electrical, controls, instrumentation, communications, and automation faults.Support installation, startup, commissioning, and validation of new equipment and control systems.Develop and maintain standardized programming practices, electrical documentation, and control narratives.Maintain backups and revision control for PLC, HMI, SCADA, and drive programs.Develop, maintain, and improve Ignition SCADA applications, including dashboards, alarms, reports, historian configurations, security, and scripting.Support manufacturing data acquisition, visualization, and system integration initiatives.Maintain SQL databases supporting manufacturing operations and develop queries, stored procedures, reports, and analytics tools.Integrate production equipment with SQL-based ERP and manufacturing systems.Support manufacturing KPI reporting, production analytics, and operational decision-making.Configure, maintain, and troubleshoot industrial Ethernet, EtherNet/IP, managed switches, VLAN communications, and other industrial network devices.Coordinate with Corporate IT on cybersecurity, firewall configurations, network architecture, and system updates.Troubleshoot equipment failures with maintenance technicians, engineers, and operations personnel.Lead root cause investigations and develop corrective actions for recurring equipment and process issues.Develop preventive and predictive maintenance strategies for automation and controls systems.Lead controls modernization, automation upgrades, capital projects, and continuous improvement initiatives.Evaluate obsolete automation hardware and develop replacement or migration strategies.Manage contractor and OEM activities during equipment repairs, upgrades, and installations.Provide technical training and mentorship to maintenance personnel and electrical trades.Develop engineering solutions that improve safety, reliability, productivity, quality, and operational efficiency.Required Qualifications / Must-Have QualificationsA bachelor's degree in Electrical Engineering, Controls Engineering, Computer Engineering, or a related engineering discipline is required, OR a licensed Journeyman Electrician with advanced PLC/automation certification and equivalent industrial experience.A minimum of 5 years of industrial automation and controls experience in a manufacturing environment is required.Experience programming Allen-Bradley PLC platforms, including ControlLogix and CompactLogix, is required.Experience with Allen-Bradley PowerFlex drives is required.Experience developing and troubleshooting HMI systems is required.Experience with Ignition SCADA is required.Strong SQL database knowledge and development experience are required.Experience integrating manufacturing equipment with ERP and manufacturing systems is required.Knowledge of EtherNet/IP and industrial networking systems is required.Strong electrical and controls troubleshooting skills are required.Excellent communication, organizational, and project management skills are required.Must be comfortable working directly on the production floor in a heavy industrial manufacturing environment.Must be able to participate in equipment troubleshooting, testing, commissioning, maintenance outages, startups, and capital project installations.Must follow company and regulatory safety procedures.Must be available for occasional after-hours, weekend, or emergency support when required for critical production equipment.Preferred QualificationsExperience in aluminum extrusion, metals manufacturing, or other continuous manufacturing operations.Experience with Rockwell Studio 5000.Experience with FactoryTalk products.Experience with OPC UA communications.Knowledge of industrial cybersecurity best practices.Experience with SQL Server Reporting Services (SSRS).Experience with Microsoft Power BI or Microsoft Fabric.Understanding of ISA-95 manufacturing architecture.What You’ll BringYou’ll bring a hands-on approach to industrial automation, strong PLC and controls expertise, and the ability to move comfortably between production-floor troubleshooting, automation programming, SCADA development, manufacturing data analysis, and engineering projects. The ideal candidate is a practical problem solver who values safety, equipment reliability, operational excellence, and continuous improvement.