Lead Controls Engineer

seeking an experienced Lead Controls Engineer to support industrial automation, plant-floor controls, and manufacturing operations at its Holcomb, Kansas facility.

The ideal candidate will have strong hands-on experience with PLC programming and troubleshooting, particularly Schneider Electric/Modicon systems. This role involves supporting automated production lines, conveyors, material-handling equipment, SCADA/HMI systems, industrial scanning devices, and plant-floor communication networks.

The engineer will troubleshoot complex control-system issues, identify root causes, support legacy equipment, and contribute to controls upgrades and modernization initiatives. The position also requires technical leadership, cross-functional collaboration, and ensuring reliable plant operations.

Key Responsibilities

• Lead troubleshooting, programming, commissioning, and maintenance of PLC-based industrial control systems.
• Diagnose and resolve issues involving Schneider Electric/Modicon PLCs, ladder logic, structured programming, and I/O mapping.
• Troubleshoot automated production equipment, conveyors, motors, drives, sensors, photo eyes, interlocks, and sequencing systems.
• Support and troubleshoot HMI/SCADA platforms, particularly Ignition and iFix.
• Integrate and troubleshoot industrial barcode scanners, vision systems, and identification equipment, including Keyence, Cognex, and SICK.
• Diagnose communication issues between PLCs, HMIs, scanners, field devices, and plant-floor systems.
• Interpret electrical schematics and trace faults across electrical, controls, communication, and equipment systems.
• Support both legacy and modern automation systems, including upgrades, replacements, and modernization projects.
• Develop, review, and modify control-system specifications, configurations, and programs.
• Develop and execute integrated test plans to verify system functionality and reliability.
• Follow established engineering standards, system development lifecycle methodologies, and plant procedures.
• Provide technical direction and recommendations to engineering teams, vendors, and management.
• Collaborate with cross-functional teams to improve equipment reliability, minimize downtime, and maintain production efficiency.

Required Qualifications

• Bachelor's degree in Computer Science, Information Systems, Engineering, or another technical field; equivalent experience may be considered.
• At least 6 years of experience in Information Systems, industrial controls, automation, or a related technical field.
• Proven programming and troubleshooting experience in industrial control environments.
• Strong hands-on PLC programming, commissioning, and troubleshooting skills.
• Experience with ladder logic, structured programming, I/O mapping, and HMI integration.
• Ability to read and interpret electrical schematics.
• Strong understanding of SCADA systems, scripting, server-based technologies, SQL, and industrial control applications.
• Experience with system development lifecycle methodologies, system testing, and technical documentation.
• Excellent problem-solving, communication, and cross-functional collaboration skills.
• Ability to communicate technical information effectively to technical and non-technical stakeholders.

Preferred Technical Skills

• PLC/Controls: Schneider Electric/Modicon PLCs, ladder logic, structured programming, and troubleshooting.
• Plant Automation: Automated production systems and manufacturing equipment.
• Conveyance Systems: Conveyors, motors, drives, sensors, photo eyes, interlocks, and sequencing.
• SCADA/HMI: Ignition and iFix.
• Industrial Scanning/Vision: Keyence, Cognex, and SICK systems.
• Industrial Communications: Troubleshooting communication between PLCs, HMIs, scanners, and field devices.
• Controls Modernization: Legacy equipment support, system upgrades, and replacements.
• Programming & Data: SQL, scripting, server-based systems, and 4GL programming.