CONTROLS ENGINEER – MANUFACTURING AUTOMATION
# CONTROLS ENGINEER – MANUFACTURING AUTOMATION **FUTURE FOAM** · Fullerton, CA 92831 · `On-site` 🕒 **Статус:** *Опубликовано: сегодня* · *Источник: Indeed* --- ### About the Role Future Foam, Inc., is a leading manufacturer of polyurethane foam products that has been family-owned for over 60 years. Its primary focus is to provide excellent quality and service throughout the manufacturing process. With over 30 facilities across the United States and internationally, we take pride in having a culture that fosters an open, trusting, and collaborative work environment. Most importantly, we put safety first. Position Overview We are seeking a hands-on Controls Engineer to support, troubleshoot, improve, and commission automated manufacturing equipment at our Fullerton, California facility. This position is for an engineer comfortable working directly on the production floor and diagnosing real equipment problems—not solely developing software from an office. The successful candidate will have strong practical experience with Allen-Bradley PLCs, Studio 5000, VFDs, servo/motion systems, industrial electrical schematics, sensors and instrumentation, HMIs, and industrial networks. The Controls Engineer will work closely with Engineering, Maintenance, Production, OEMs, electricians, and contractors to maximize equipment reliability and manufacturing performance. Key Responsibilities: Troubleshoot PLC-controlled manufacturing equipment and automated production systems. Develop, modify, test, and document Allen-Bradley ControlLogix and CompactLogix PLC programs using Studio 5000. Diagnose machine sequence, permissive, interlock, I/O, communication, and field-device problems. Configure and troubleshoot Allen-Bradley PowerFlex VFDs and motor-control systems. Support and troubleshoot servo motors, servo drives, encoders, homing, positioning, motion sequences, and related motion-control systems. Read and troubleshoot industrial electrical schematics, control circuits, motor circuits, and panel wiring. Troubleshoot digital and analog I/O, photoeyes, proximity sensors, encoders, pressure/temperature transmitters, flow devices, and other industrial instrumentation. Support 4–20 mA, 0–10 V, RTD, and other common industrial signals. Configure and troubleshoot EtherNet/IP communications among PLCs, VFDs, remote I/O, HMIs, and other automation devices. Support industrial Ethernet switches, IP addressing, network segmentation/VLAN concepts, DeviceNet, IO-Link, and other plant networks as applicable. Develop and troubleshoot HMI applications and operator interfaces. Provide hands-on support during equipment failures and production downtime. Perform root-cause analysis and develop permanent corrective actions for recurring controls failures. Support new equipment installations, I/O checkout, startup, commissioning, and production validation. Work with OEMs and integrators on equipment modifications and new automation projects. Maintain current PLC/HMI/VFD backups, electrical drawings, network documentation, device parameters, and change records. Assist with controls-system upgrades, obsolescence planning, standardization, and continuous improvement. Required Qualifications Hands-on industrial controls or automation experience in a manufacturing environment. Strong Allen-Bradley PLC troubleshooting and programming experience. Practical experience with ControlLogix and/or CompactLogix and Studio 5000. Ability to read and troubleshoot industrial electrical schematics. Experience troubleshooting VFD-controlled motors and industrial control circuits. Ability to troubleshoot field I/O, sensors, relays, contactors, instrumentation, and machine interlocks. Understanding of industrial Ethernet and EtherNet/IP communications. Strong systematic troubleshooting and root-cause problem-solving skills. Ability and willingness to work directly on the manufacturing floor with Maintenance and Production. Ability to document program, parameter, wiring, and system changes. Preferred Experience Allen-Bradley PowerFlex 525, 753, and/or 755 VFDs. Servo and motion-control systems, including encoders, homing, positioning, scaling, and tuning. FactoryTalk View ME/SE and PanelView Plus HMIs. DeviceNet and IO-Link. Managed industrial Ethernet switches, including Rockwell Stratix. Analog instrumentation including 4–20 mA and 0–10 V. Industrial temperature, pressure, flow, and position instrumentation. 480 VAC three-phase motor-control systems. Machine safety circuits and safety PLC concepts. Equipment commissioning and startup. Controls-panel and electrical-system design. Electrical or similar electrical CAD experience. Manufacturing automation project execution and OEM/integrator coordination. The Type of Controls Engineer We’re Looking For We are looking for someone who can connect a laptop to a PLC, read the logic, understand the electrical schematic, walk to the machine, inspect the field devices, make appropriate measurements safely, identify the actual root cause, implement a controlled correction, and verify that the machine operates properly. A typical day may include diagnosing a conveyor that will not start, identifying a failed permissive, troubleshooting a PowerFlex drive at 0 Hz, resolving an EtherNet/IP I/O connection, correcting an analog signal problem, investigating a servo positioning fault, modifying a PLC sequence, or commissioning new equipment. Safety The Controls Engineer must follow company Lockout/Tagout and electrical-safety procedures and incorporate safe design and troubleshooting practices into all work. Energized electrical work or testing, when applicable, must follow facility requirements and applicable regulations. Why This Position This role provides the opportunity to work directly with a wide variety of industrial automation systems and manufacturing equipment. It is well suited for an engineer who enjoys hands-on troubleshooting, automation projects, machine improvement, and seeing controls changes produce measurable results on the manufacturing floor. Job Type: Full-time Pay: $103,102.15 - $113,824.64 per year Benefits: 401(k) Dental insurance Employee assistance program Flexible spending account Health insurance Life insurance Paid time off Parental leave Vision insurance People with a criminal record are encouraged to apply Application Question(s): How many years of hands-on experience do you have programming and troubleshooting Alan-Bradley PLC's? Which Alan Bradley platforms have you personally programmed or troubleshoot? What is your hands-on proficiency with Studio 5000 Logix Designer? Advanced – independently develop in troubleshoot programs Proficient– Regularly modify and troubleshoot programs Basic – limited changes/monitoring No hands-on experience Which PLC programming languages have you used hands-on? Ladder logic Structure Text Function Block Diagram Sequential Function Chart None Which VFD's have you personally configured or troubleshoot? Alan-Bradley PowerFlex 525 PowerFlex 753/755 Other PowerFlex models Other industrial VFD brands None What is your hands-on experience with servo/motion systems? Extensive – programming, commissioning, tuning and troubleshooting Moderate– regular troubleshooting/configuration Limited exposure None Which industrial communications/network technologies have you personally troubleshot? Ethernet/IP DeviceNet ControlNet IO-Link Modus TCP Managed industrial Ethernet switches None Which HMI platforms have you personally programmed or troubleshoot? FactoryTalk View ME FactoryTalk View SE PanelView Plus Ignition AVEVA/Wonderware Other industrial HMI None This is a hands-on position requiring regular work on the manufacturing floor, including equipment troubleshooting, start up, commissioning, and working directly with maintenance and production. Are you comfortable with this requirement? Briefly describe a manufacturing controls problem you personally diagnose and corrected. Include the equipment symptoms, how you diagnosed it, the root cause, and what you did correct it Briefly described the most significant Allen – Bradley PLC project or program modification you personally completed. State the PLC platform, your responsibilities, and what you programmed or changed. Which devices/signals have you personally troubleshoot? 24 VDC digital I/O 4–20 mA analog signals 0–10 V analog signals RTD's/temperature sensors Pressure/flow transmitters Encoders Photoeyes/proximity sensors None Education: Bachelor's (Preferred) Work Location: In person
Наблюдалась 2026-09-15, впервые 2026-09-14, источник — Indeed.