Operations and Controls Engineer

Position Summary

The Operations and Controls Engineer is responsible for supporting, improving, and expanding the automation and operational technology systems used throughout a packaging facility and warehouse.

Hands-on PLC programming experience is an absolute requirement for this position. The individual must be capable of troubleshooting PLC-controlled equipment, diagnosing controls-related failures, reviewing and modifying PLC logic, and assisting Maintenance with the diagnosis and repair of automated packaging equipment.

While equipment troubleshooting and controls support are critical responsibilities, much of the role will focus on technology-driven continuous improvement. This includes improving equipment reliability, increasing visibility into operational performance, developing data collection and reporting capabilities, implementing automation improvements, and using technology to identify and resolve recurring equipment and system issues.

Work Location: West Jefferson, OH

Travel: Up to 30%

Competitive Total Rewards: Competitive salary of  $100,000- $120,000.00 , plus bonus, along with comprehensive benefits, including medical, dental, and vision insurance, 401(k) with company match, generous PTO, sick time, and company holidays. Compensation is based on experience, skills, and education.

Essential Responsibilities

PLC & Controls Support

• Provide technical support to Maintenance for troubleshooting and repair of automated packaging and material handling equipment.
• Diagnose PLC, HMI, sensor, communication, drive, servo, and other controls-related equipment failures.
• Review, troubleshoot, modify, and develop PLC programs as required.
• Support equipment downtime investigations and identify root causes of recurring controls-related failures.
• Troubleshoot industrial communication networks and communication between automated equipment.
• Support commissioning, installation, and startup of new packaging, conveying, and warehouse automation equipment.
• Maintain backups and documentation for PLC programs, HMI applications, drive parameters, and other controls systems.
• Work with equipment manufacturers and system integrators to resolve complex automation issues.
• Develop controls standards and programming practices that improve long-term equipment reliability and maintainability.

Technology & Data-Driven Continuous Improvement

• Identify opportunities to improve equipment performance, reliability, and operational visibility through automation, controls, data, and technology.
• Develop and implement equipment monitoring, downtime tracking, production reporting, and performance visualization solutions.
• Collect and analyze equipment and operational data to identify recurring failures, performance losses, and improvement opportunities.
• Improve the availability and accuracy of data used by Operations, Maintenance, Engineering, and facility leadership.
• Identify opportunities to automate manual data collection, reporting, and monitoring activities.
• Use equipment data to support root cause analysis and reliability improvement efforts.
• Evaluate new technologies that can improve equipment monitoring, diagnostics, connectivity, and performance.
• Develop technology-based solutions that improve the ability of Operations and Maintenance teams to identify and respond to equipment issues.
• Establish standards for equipment data collection, reporting, and system integration where appropriate.

Automation & Systems Integration

• Support implementation of new packaging equipment, conveyor systems, robotics, vision systems, inspection equipment, and warehouse automation.
• Integrate new equipment with existing plant controls and operational systems.
• Support communication between PLC-controlled equipment and higher-level production or reporting systems.
• Develop and maintain interfaces between automated equipment and data collection or reporting platforms.
• Evaluate sensors, controls hardware, automation technologies, and software that can improve facility performance.
• Support implementation of machine monitoring and diagnostic capabilities.
• Develop and maintain technical documentation including control system architecture, network configurations, equipment interfaces, and operating standards.
• Coordinate with IT when projects require industrial networking, system connectivity, cybersecurity, or remote access.

Operational Technology Support

• Troubleshoot basic industrial Ethernet, IP addressing, managed switches, and equipment communication issues.
• Support industrial computers, HMIs, PLC networks, and other systems associated with automated equipment.
• Assist with equipment data collection and integration where operationally beneficial.
• Work with corporate IT to maintain reliable and secure connectivity for plant-floor automation systems.
• Support connectivity between plant-floor equipment and approved reporting, database, or enterprise systems.

This position is not eligible for immigration sponsorship.

#LI-SALARY

• Bachelor's degree in Electrical Engineering, Controls Engineering, Automation Engineering, Mechatronics, Industrial Engineering, or a related technical field preferred. An equivalent combination of technical education and relevant industrial experience may be considered.
• Hands-on experience with PLC programming, troubleshooting, and industrial automation is required, regardless of educational background.
• Proven ability to diagnose, troubleshoot, and repair automated industrial equipment.
• Working knowledge of HMIs, VFDs, sensors, industrial control systems, and industrial networking.
• Strong technical troubleshooting, problem-solving, and analytical skills.
• Ability to collaborate effectively with Maintenance, Operations, Engineering, and IT teams.

• Experience with Allen-Bradley/Rockwell Automation PLCs and Studio 5000.

• Experience with packaging equipment, conveyors, robotics, or warehouse automation systems.

• Experience with industrial data collection, reporting, and visualization tools.

• Familiarity with AutoCAD, Power BI, EtherNet/IP, or similar technologies.

• Experience in food production, consumer packaged goods, manufacturing, or distribution environments.