Job Description
About the Job
Controls Specialist
PLC Support / Pilot Line / Manufacturing Automation
Controls & Automation Consultants LLC is a systems integrator and engineering services provider supporting industrial automation, controls engineering, and manufacturing technology needs for customers across the United States and internationally.
CAC is seeking experienced Controls Specialists for immediate opportunities across California, Pennsylvania, and Texas. These roles will support automated manufacturing equipment, PLC-controlled systems, pilot production lines, installation activities, startup support, and commissioning activities in fast-paced industrial manufacturing environments.
These role is well suited for hands-on controls professionals with strong troubleshooting skills, the ability to read and interpret electrical documentation, and experience supporting PLC-based automation systems on the manufacturing floor.
Selected candidates will work closely with controls engineers, installation leads, commissioning teams, maintenance, and manufacturing operations to support pilot line development, production readiness, equipment installation, troubleshooting, startup, and commissioning activities.
The environment may include:
- Automated production equipment
- PLC-controlled machinery
- HMIs
- Industrial networks
- Sensors and actuators
- Drives and remote I/O
- Control panels
- Electrical documentation
- Calibration documentation
- Related automation hardware
Reporting Structure
The Controls Specialist will work under the direction of:
- Lead engineers
- Controls engineers
- Installation leads
- Commissioning leads
- Maintenance leadership
- Manufacturing operations teams
These teams are responsible for automation system performance, simulation testing, staging, pilot line readiness, equipment installation, production uptime, startup support, and commissioning execution.
Key Responsibilities
- Troubleshoot and resolve machine faults, PLC alarms, sensor issues, actuator issues, communication faults, wiring issues, and other controls-related problems across automated manufacturing equipment and production systems.
- Support pilot line automation equipment during installation, development, testing, production readiness, startup, and commissioning phases.
- Provide hands-on controls support for PLC-controlled equipment, industrial automation systems, automated production cells, and manufacturing support equipment.
- Monitor, diagnose, and support PLC-controlled equipment using platforms such as Codesys, Inovance, Siemens, Allen-Bradley, Omron, Mitsubishi, or similar systems.
- Troubleshoot PLC hardware and related automation devices, including I/O, logic, communications, wiring, and equipment interface issues.
- Review and troubleshoot PLC logic, tags, alarms, function blocks, ladder logic, structured text, and equipment sequences to support installation, startup, commissioning, and production activities.
- Read and interpret electrical wiring diagrams, electrical schematics, panel layouts, equipment manuals, installation drawings, calibration documentation, and technical procedures.
- Read and follow electrical manuals, device manuals, calibration documentation, startup procedures, checkout procedures, and equipment support documentation.
- Work from punchlists to complete assigned installation, checkout, troubleshooting, verification, documentation, and corrective action items.
- Follow direction from lead technicians, lead engineers, controls engineers, installation leads, and commissioning leads during equipment installation, startup, and commissioning activities.
- Perform field verification of wiring, terminations, devices, sensors, actuators, I/O points, panels, and control system components.
- Perform I/O checkout, device verification, sensor validation, actuator testing, network checks, calibration support, loop checks, and functional testing for automated equipment.
- Identify wiring, installation, calibration, documentation, or equipment discrepancies and communicate findings clearly to the appropriate lead or engineering team.
- Create redlines and markups to electrical drawings, wiring diagrams, schematics, installation drawings, calibration documents, punchlists, and other technical documentation when field changes or discrepancies are identified.
- Assist controls engineers with PLC testing, validation, documentation updates, equipment checkout, and minor program changes as directed.
- Support commissioning, startup, and production ramp-up activities for new or modified manufacturing systems.
- Diagnose and support resolution of industrial communication issues involving Ethernet-based networks, PLC communications, remote I/O, HMIs, drives, and connected automation devices.
- Support HMI troubleshooting, alarm review, operator interface testing, equipment status review, and production support activities.
- Collaborate with engineering, maintenance, manufacturing, equipment, installation, and IT/OT teams to improve equipment reliability, installation quality, startup readiness, and production uptime.
- Document recurring automation issues, assist with root cause analysis, and support corrective action implementation.
- Support continuous improvement initiatives related to equipment performance, downtime reduction, fault recovery, startup readiness, installation quality, and operational efficiency.
- Assist with maintaining electrical drawings, controls documentation, PLC backups, calibration records, troubleshooting guides, startup checklists, punchlists, and automation support procedures.
- Escalate complex PLC, controls, robotics, network, wiring, installation, calibration, or equipment issues to the appropriate engineering or technical support teams.
Required Qualifications
- Minimum two-year Associate degree, technical diploma, or equivalent technical training in Automation, Robotics, Electrical Technology, Electronics Technology, Mechatronics, Industrial Maintenance, or a related technical discipline.
- Minimum 5 - 8 years of hands-on technical experience supporting industrial automation, manufacturing equipment, PLC-controlled systems, equipment installation, startup support, commissioning, or production control systems.
- Hands-on experience troubleshooting PLC-controlled manufacturing equipment and industrial automation systems.
- Experience with PLC troubleshooting platforms such as Codesys, Inovance, Siemens, Allen-Bradley, Omron, Mitsubishi, or similar systems.
- Ability to troubleshoot PLC logic, I/O, alarms, sensors, actuators, drives, HMIs, safety devices, wiring, terminations, panels, and controls hardware.
- Experience reviewing and troubleshooting ladder logic, structured text, function blocks, tags, alarms, and equipment sequences.
- Ability to read and interpret electrical wiring diagrams, electrical schematics, panel layouts, equipment manuals, calibration documentation, installation documentation, and technical procedures.
- Ability to work from punchlists and complete assigned troubleshooting, installation, checkout, documentation, and verification tasks.
- Ability to create accurate redlines, markups, and field notes when drawings, wiring, devices, calibration records, or documentation require updates.
- Knowledge of industrial Ethernet networks, PLC communications, remote I/O, and related communication technologies.
- Ability to perform equipment checkout, I/O verification, startup support, calibration support, commissioning assistance, and functional testing.
- Experience working in manufacturing, high-volume production, pilot line, startup, equipment installation, commissioning, or industrial maintenance environments.
- Ability to follow direction from leads, work safely in an active installation or manufacturing environment, and communicate status, issues, and risks clearly.
- Ability to work safely around automated equipment, electrical panels, production machinery, and energized industrial systems within approved safety boundaries.
- Ability to work on-site at assigned customer locations in California, Pennsylvania, or Texas.
Preferred Qualifications
- Direct hands-on experience with Codesys, Inovance PLC platforms, Studio5000, Siemens TIA Portal, Omron etc.
- Experience supporting automated lines, new equipment launches, manufacturing startups, equipment installations, commissioning activities, or production ramp-up activities.
- Experience supporting automated production systems used in advanced manufacturing, automated assembly, material handling, high-volume production, equipment installation, or large-scale industrial environments.
- Experience supporting robotic systems, automated production cells, manufacturing equipment, test systems, or industrial process equipment.
- Experience working with multiple PLC platforms, including Inovance, Siemens, Allen-Bradley, Omron, Mitsubishi, or similar systems.
- Familiarity with safety interlocks, machine guarding, safety circuits, safety PLCs, and production support activities.
- Experience supporting HMI or SCADA platforms used in manufacturing environments.
- Experience with VFDs, servo drives, sensors, barcode readers, vision systems, industrial PCs, remote I/O, and manufacturing data systems.
- Experience performing I/O checks, loop checks, calibration checks, device validation, installation verification, and commissioning support.
- Basic understanding of programming concepts, scripting, equipment data collection, or manufacturing software systems.
- Experience using electrical drawings, controls schematics, network diagrams, PLC documentation, calibration records, punchlists, and troubleshooting procedures.
- Mandarin speaking ability is preferred but not mandatory.
Assignment Highlights
- Support opportunities across multiple California, Pennsylvania, and Texas locations.
- Support automation systems tied to pilot line development, manufacturing operations, equipment installation, and future startup and commissioning activities.
- Work with PLC-controlled equipment, HMIs, industrial networks, electrical documentation, calibration documentation, and automated production systems.
- Participate in installation support, punchlist execution, redline documentation, troubleshooting, system testing, equipment checkout, startup support, commissioning assistance, and continuous improvement initiatives.
- Collaborate with engineering, maintenance, equipment, installation, IT/OT, and manufacturing teams in a fast-paced production environment.
- Initial support is expected to align with production readiness and resource ramp-up activities, with future support needs tied to startup and commissioning phases.
- Project duration is expected to be 6+ months for the right candidate.
- Expense package is provided outside of the hourly rate.
- Opportunity for assignment extensions based on project requirements, production ramp-up, startup support, commissioning needs, and business requirements.
Employment Type
