Controls & Automation Technician

Job Description

Job Summary:

The Controls & Automation Technician plays a critical role in supporting and maintaining automated systems and PLC-controlled equipment throughout the plant. The ideal candidate will have hands-on experience in PLC programming, troubleshooting, and optimizing controls systems in a manufacturing setting—preferably within the food or dairy industry. All work must be performed in compliance with Good Manufacturing Practices (GMP) and Safe Quality Food (SQF) standards.

Schedule: 8am - 5pm, Monday - Friday, On call

Key Responsibilities:

Troubleshoot, repair, and maintain PLCs (Allen-Bradley preferred) and associated control systems.

Program and modify logic on PLCs, HMIs, VFDs, and SCADA systems to optimize plant performance.

Support day-to-day operations by responding quickly to automation-related issues on production lines.

Collaborate with maintenance, production, and operations to implement control upgrades and process improvements.

Maintain accurate documentation of all control system changes and modifications.

Ensure compliance with safety and food quality standards.

Perform preventive maintenance on automation and instrumentation systems.

Train maintenance personnel and operators on system operation and troubleshooting techniques

Job Functions:

Adherence to Safety & Quality Standards

Follow all health and safety policies/procedures and GMPs and wear the required personal protective equipment (PPE).

Comply with food quality and safety standards, including SQF requirements.

Troubleshooting & Maintenance

Lead or assist in equipment failure investigations, working closely with production teams to identify root causes.

Perform preventive maintenance and repairs on mechanical, electrical, and electronic systems (PLC hardware, VFDs, HMIs).

Diagnose and troubleshoot PLC and automation issues, including faulty components, wiring, or programming logic.

Calibrate and test equipment to ensure performance accuracy and compliance with specifications.

Equipment Upgrades & Installations

Installed, tested, and started up new food manufacturing, packaging, and processing equipment, ensuring alignment with production requirements.

Modify existing programs for system optimization, new process implementations, and enhanced safety protocols.

Interface with machine tools, special equipment, or test modules; perform modifications to improve or update systems.

Maintain accurate records of all maintenance activities, repairs, programming changes, and upgrades.

PLC Programming & Optimization

Use RS Logix 5000, RS Logix 500, and RS Logix 5 for machine troubleshooting, going online with ControlLogix, CompactLogix, and SLC500.

Upload, download, and edit PLC programs as required, ensuring minimal disruption to production.

Understand and implement advanced programming concepts (AOIs, UDTs, arrays) and manage various tag types/references.

Perform system upgrades to optimize production efficiency, safety, and reliability.

HMI & Automation Control

Configure and replace PanelView or PanelView Plus HMIs, downloading applications using Panel Builder 32 or RS View Studio Machine Edition.

Develop and modify HMI screens, animations, and scripts to align with current processes and operator needs.

Ensure accurate data exchange between the HMI and the PLC, troubleshooting communication or tag reference issues as they arise.

Continuous Improvement & Collaboration

Participate in a continuous improvement culture; identify and suggest process enhancements to boost system reliability and reduce costs.

Train team members on basic PLC functions and troubleshooting, fostering a collaborative knowledge-sharing environment.

Build positive, respectful relationships with managers, supervisors, maintenance technicians, and machine operators, ensuring open communication.

Required Skills:

PLC Programming: Expert in RS Logix 5000 and 500, with experience troubleshooting and editing code on ControlLogix, CompactLogix, and SLC500 platforms.

SCADA Systems: Experience with or exposure to SCADA platforms (Wonderware preferred) for system monitoring and interface.

Electrical Proficiency: Skilled in working with up to 480VAC, reading schematics, and using electrical test equipment.

Drive Systems: Capable of configuring and replacing AB PowerFlex (40, 400, 525), Siemens, and Mitsubishi VFDs.

HMI Development: Experience developing and modifying PanelView or PanelView Plus HMI applications.

AutoCAD: Basic to intermediate ability to read and modify drawings, create component blocks, and work with layers.

Documentation & Communication: Strong written and verbal communication skills, including Microsoft Office proficiency for SOPs, OPLs, and work instructions.

Analytical Thinking: Capable of dissecting complex automation logic and troubleshooting root causes effectively.

Education & Experience:

Minimum 2+ years of industrial maintenance experience, preferably in a food manufacturing environment.

Proven expertise in Rockwell/Allen-Bradley PLCs, drive systems, and electrical/electronic troubleshooting.

Certifications:

Rockwell Logix Programmer certification (or equivalent) preferred.

Environment:

Fast-paced food manufacturing setting with moving equipment, elevated noise levels (hearing protection required), and variable temperatures (hot, cold, wet conditions).

Regular exposure to dust, vibration, and confined spaces.

Frequent interaction with cleaning chemicals and sanitation protocols.

Physical Demands:

Work is performed in a fast-paced, clean manufacturing environment that may be hot, wet, loud, and involve regular exposure to chemicals used in sanitation and production processes.

Requires frequent standing, walking, bending, squatting, twisting, and pushing.

Ability to lift and carry up to 50 pounds repetitively.

Manual dexterity and hand-eye coordination are needed for equipment operation, control systems, and precision work.

Visual requirements include visual acuity (seeing fine details) and accurate color perception for interpreting schematics, identifying wires, and monitoring safety indicators.

Must be able to meet deadlines under production demands with a strong emphasis on accuracy and safety.

Schedule may include weekdays, weekends, second/third shifts, holidays, and overtime as needed.

Full-time