Controls Engineer - High-Volume Manufacturing

Flex

  • Buffalo Grove, IL
  • Permanent
  • Full-time
  • 21 days ago
Job Posting Start Date 08-14-2025 Job Posting End Date 10-14-2025Flex is the diversified manufacturing partner of choice that helps market-leading brands design, build and deliver innovative products that improve the world.A career at Flex offers the opportunity to make a difference and invest in your growth in a respectful, inclusive, and collaborative environment. If you are excited about a role but don't meet every bullet point, we encourage you to apply and join us to create the extraordinary.Job SummaryJOB DESCRIPTIONThe Controls Engineer is a newly created, full-time position, based in Buffalo Grove, IL. It will provide support and technical expertise in the areas of controls and electronic circuitry in order to achieve safety, quality, and productivity targets in a medical device manufacturing plant. Primary focus will be on controls improvements and troubleshooting of high volume automated medical device assembly equipment and associated electrical wiring/devices, instrument, embedded systems, motion control and inspection systems. In addition, it is expected that this individual will assist and provide training to maintenance, production or other personnel as needed with technical or troubleshooting related matters. The selected candidate will have experience in the design, installation, and upkeep of PLC based controls in a manufacturing environment.What you will be doing:
  • Lead or support maintenance teams in troubleshooting elusive problems resulting in downtime or quality issues. Identify and correct causes of chronic equipment failures or issues.
  • Assist with development and implementation of plans to achieve highly effective controls troubleshooting and repair, while minimizing downtime.
  • Provide control of machine software, firmware and user access security.
  • Propose, evaluate risk and implement PLC program and other software/firmware or hardware changes needed to improve safety, yield and productivity.
  • Completing change control documentation, including change documentation, risk assessment and justification.
  • Define equipment maintenance/preventative maintenance requirements and procedures.
  • Identify root-causes of equipment failures and slowdowns, develop and implement corrective actions.
  • Develop troubleshooting and repair skills of Controls and Automation Technicians.
  • Provide on-call support for system outages and incidents.
  • Development of User Requirement Specifications for new equipment or equipment updates.
  • Work with Automation and Validation Engineers to develop test script to validate software/firmware updates.
  • Support commissioning and validation of new equipment and/or implementation and testing of changes to existing equipment.
Qualifications (Required Education, Experience, etc.):
  • A Bachelor of Science degree in Electrical Engineering or equivalent coupled at least 3 years of industrial controls experience in high volume manufacturing environment.
  • Proficiency programming and troubleshooting Allen Bradley Control Logics PLCs and Human Machine Interface (HMI / GUI )
  • Established user of RSLOGIX5000, Logix Designer, Studio 5000
  • Ability to design fault-tolerant systems with error handling and recovery.
  • General understanding of factory LAN/WAN ethernet networks and ability to setup devices with IP addresses or nodes
  • Proficiency selecting appropriate circuit protectors, wire and cable.
  • Experience selecting, configuring and installing: sensors, safety hardware, PLC hardware, remote I/O, VFDs and instrumentation.
  • Knowledge of controls devices and experience troubleshooting.
  • Effective written and verbal communication skills.
DESIRED SKILLS (Ideal/Optional Experience, etc.):
  • Experience with Vision systems is a plus (Cognex, Keyence, Fanuc) is a plus.
  • Experience programming/troubleshooting Siemens PLC, Step7.
  • Proficient with: RSLOGIX5000, Logix Designer, Studio 5000, Factory Talk SE, and Ignition.
  • Experience setting up/tuning and troubleshooting Allen Bradley Power-Flex variable frequency drives and Kinetix multi-axis servo drives.
  • Working knowledge of:
  • Field bus Networks (ProfiNet, DeviceNet, Ethernet/IP, Safety rated field bus networks).
  • Radio frequency identification devices (RFID) and all the accompanying components (Receiver, antenna, puck, reader)
  • PID tunning and closed feedback loops
  • Serial communication (RS-232, RS-422, RS-485, ProfiBus, Modbus RTU, Data Highway) between PLCs, instruments and microcontrollers
  • Ethernet communications between machine PLCs and embedded data collection systems
JT05AA01CH12MS14CC11What you'll receive for the great work you provide:
  • Full range of medical, dental, and vision plans
  • Life Insurance
  • Short-term and Long-term Disability
  • Matching 401(k) Contributions
  • Vacation and Paid Sick Time
  • Tuition Reimbursement
Pay Range (Applicable to Illinois)$63,500.00 USD - $87,300.00 USD AnnualJob Category Production EngineeringIs Sponsorship Available? NoFlex is an Equal Opportunity Employer and employment selection decisions are based on merit, qualifications, and abilities. We do not discriminate based on: age, race, religion, color, sex, national origin, marital status, sexual orientation, gender identity, veteran status, disability, pregnancy status, or any other status protected by law. We're happy to provide reasonable accommodations to those with a disability for assistance in the application process. Please email accessibility@flex.com and we'll discuss your specific situation and next steps (NOTE: this email does not accept or consider resumes or applications. This is only for disability assistance. To be considered for a position at Flex, you must complete the application process first).

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