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Job Title: Controls EngineerJob Description

The Controls Engineer is responsible for the Technical Support functions for power and distribution systems planning and management, electrical control systems, process planning, and process improvements. This role involves the different phases of engineering projects from concept through ongoing production. The incumbent participates in activities such as the design and evaluation of processes, logic development for programmable logic controllers, design and implementation of electrical controls or distribution systems, coordination of the plant’s electrical distribution system, and preparation of specifications for bids and proposals. The individual must assist in maintaining technological control over all processes and maintain a current back-up of all programs or parameters including documentation for electrical control systems such as PLC’s, drives, and operator interface terminals. Additionally, the Controls Engineer must maintain electrical schematics for all equipment control systems in a central location as well as at the respective equipment.

Responsibilities

• Assist plant maintenance in troubleshooting and repair of electrical systems.

• Develop hardware requirements for electrical control systems for process equipment based on required process input and outputs.

• Develop control programs for programmable logic controllers and operator interface terminals to reflect the process.

• Maintain and troubleshoot all PLC equipment hardware and software for the plant’s processes.

• Calculate and design power requirements for new power feed installations to new process equipment or facilities.

• Determine size and appropriate ratings of transformers, wire, conduit, circuit protection, and grounding systems, complying with national electrical codes.

• Investigate and determine the adaptability of new electrical technologies to facilities and equipment.

• Prepare specifications and appropriations, initiate purchase of capital equipment, and oversee their installation and implementation.

• Manage the existing and new installations of the plant’s power distribution systems.

• Maintain and update any changes to current single-line electrical diagrams, panel drawings, panel or distribution centers labeling, and systems loads.

• Make recommendations to management for changes or adjustments to the power systems.

• Monitor and implement corrective actions to maintain the plant’s power factor close to unity to prevent penalties from the local power utilities.

• Provide a proactive communication link of any power demand fluctuations or modifications to plant power facilities to the local power utilities representatives.

• Monitor power systems for any unusual demands or improper operation and report any such activities to management and local utilities for corrective actions.

• Manage the existing and new installations as well as testing to the plant’s fire protection system.

• Maintain and update any changes to current system diagrams, drawings, and documentation.

• Make recommendations to management for changes or adjustments to the fire protection systems.

• Plan, design, and assist in construction and implementation of new control systems to replace antiquated or inefficient control systems on current equipment or processes.

• Develop and assist in the implementation of an electrical preventative maintenance program.

• Identify critical equipment and its electrical components and initiate predictive programs to replace worn equipment prior to failure to reduce downtime to the operations.

• Participate in cost and productivity improvement projects to reduce utility costs, high maintenance costs or excessive downtime with electrical power or control systems.

• Determine the most efficient workstation layout, machines, tools, and operations required to develop optimum line balance for sequential operations.

• Devise and develop the use of substitute equipment, tools, and operations to overcome production schedules or technical problems.

• Plan and design new processes and equipment, such as electrical control systems, jigs, fixtures, gauges, and tools.

• Develop improvements of special hydraulic, pneumatic, and electromechanical equipment.

• Monitor and control fabrication progress, establish estimates of time, material, and labor costs on projects submitted.

• Use project management methods and reports to monitor the projects.

• Participate in productivity and quality improvements by investigating, analyzing, and estimating cost reduction in proposed major changes involving department layouts, methods and operation sequence, machine utilization, tools, jigs, fixtures, and the introduction of automation.

• Investigate the availability of special machines, restrictions of workplace layout, and available facilities prior to estimation of material, labor, and machine costs.

• Obtain necessary data from various sources such as research and development engineering, quality control, and material costs required to support specific items of equipment or production schedules.

• Review and direct the integration of this information as facets of cost into bid proposals.

• Investigate new process technologies.

• Determine adaptability to facilities and product designs.

• Prepare specifications and appropriations, initiate purchases of capital equipment, and oversee their installation and implementation.

• Develop capability requirements and acceptance criteria for new and existing manufacturing processes.

• Recommend and develop flow layouts.

• Analyze all manufacturing and procedural proposals to determine the most feasible methods, the probable capital or expense expenditure requirements, and the estimated total cost.

• Prepare and present both oral and written reports to management along with detailed justification of recommendations.

• Assist in evaluating the condition and providing recommendations as to the effective maintenance of process equipment and electrical systems.

• Investigate and provide solutions for process issues to reduce defects, scrap, or re-work to improve the quality of the product and productivity of the plant.

• Determine ways to reduce work-in-process, finished goods inventories, raw materials, or non-value-added activities to aid in controlling operating cost of the facility.

• Interpret instructions and company policy to employees such as ISO 9000 documentation.

• Maintain standards of performance and training of new personnel, discipline good employee management relations, improvement of costs and quantity and quality of work of employees.

• Plan, devise and document engineering information such as operation sequences, materials, machines, equipment, tooling, and processes required to manufacture, fabricate, assemble or process electrical, mechanical, sheet metal or non-ferrous components, assemblies and systems of minimum material, labor, and machine costs.

Essential Skills

• PLC programming

• Automation

• Controls engineering

• Project management

• Bachelor’s degree in electrical engineering with five (5) years’ experience or Graduate degree in Electrical Engineering with three (3) years’ experience working in an Electrical, Manufacturing, or Process Engineering Department for a manufacturing company.

• Effective interaction and communication at the engineering technical level with people in and outside the company.

• Effective verbal and written skills to communicate technical analysis of problems and reports.

• Proficiency in PC software applications such as spreadsheets, word processors, presentations, and project management.

• No travel restrictions.

• Excellent communication skills to deal effectively with other functional areas of the company.

• Ability to work with minimal supervision.

• Independent thought, good judgment, problem-solving skills, and the ability to prioritize multiple projects.

• Experience with AutoCAD or similar computer-aided drafting.

• Knowledgeable in National Electrical Codes and industrial wiring practices.

• Significant training and experience in developing logic for programmable logic controllers and operator interface terminals and schematics for industrial electrical control systems.

• Experienced in troubleshooting industrial electrical control systems, programmable logic, and drive systems.

• Experience in Power systems planning, power distribution systems, single-phase and three-phase substation transformers, power feed sizing, motor control centers, etc.

• Experienced in various types of motors: AC, DC, single-phase motors, three-phase motors, synchronous motors, etc.

Additional Skills & Qualifications

• Working knowledge of Solid Works.

• Knowledgeable of pneumatic, hydraulic, and mechanical systems.

• Experienced in control systems integration.

Work Environment

The Controls Engineer will work in a manufacturing environment where they will interact with various electrical and mechanical systems. The role involves troubleshooting, designing, and implementing control systems. Standard office hours apply, but additional hours may be required for specific projects or emergencies. The work may involve standing for extended periods, working on-site at different plant locations, and adhering to safety protocols. The dress code is business casual with appropriate safety gear when necessary.

Pay and Benefits

The pay range for this position is $80000.00 - $108000.00

Standard benefits. Relocation. Bonus.We are committed to providing market competitive, internally equitable total rewards that allow us to attract, engage and retain the talented employees we need to deliver results for our business globally.

Our compensation and benefits programs are reviewed annually to ensure program advancement and innovation to meet the evolving needs of our employees around the world.

Workplace Type

This is a fully onsite position in Montgomery,AL.

Application Deadline

This position will be accepting applications until Feb 1, 2025.

About Actalent

Actalent is a global leader in engineering and sciences services and talent solutions. We help visionary companies advance their engineering and science initiatives through access to specialized experts who drive scale, innovation and speed to market. With a network of almost 30,000 consultants and more than 4,500 clients across the U.S., Canada, Asia and Europe, Actalent serves many of the Fortune 500.

Diversity, Equity & Inclusion

At Actalent, diversity and inclusion are a bridge towards the equity and success of our people. DE&I are embedded into our culture through:

• Hiring diverse talent

• Maintaining an inclusive environment through persistent self-reflection

• Building a culture of care, engagement, and recognition with clear outcomes

• Ensuring growth opportunities for our people

The company is an equal opportunity employer and will consider all applications without regard to race, sex, age, color, religion, national origin, veteran status, disability, sexual orientation, gender identity, genetic information or any characteristic protected by law.

If you would like to request a reasonable accommodation, such as the modification or adjustment of the job application process or interviewing process due to a disability, please email actalentaccommodation@actalentservices.com (%20actalentaccommodation@actalentservices.com) for other accommodation options.