Automation Controls Engineer

Position: 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 Ether Net/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

HMI Development & Operator Interface Design

• Design and configure operator interfaces (Panel View / 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

Vision System Integration (Cognex Designer)

• 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

SCADA, Data & Continuous Improvement

• 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)

Required Qualifications

• 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 (Panel View 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)

Plus Skills

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

TSG is an equal opportunity employer. All qualified applicants will receive consideration for employment without regard to race, color, religion, sex, sexual orientation, gender identity, national origin, disability, or status as a protected veteran.
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