Title: Controls Engineer (Electrical & Instrumentation)
Location: Virginia – September 2025
Industry: High-Performance Battery Separators
Employment: Full-time, Direct Hire
Our client, a global leader in high-performance battery separators, is seeking a Controls Engineer (Electrical & Instrumentation) to support critical manufacturing systems and automation processes at their Virginia facility. This role is responsible for maintaining and improving electrical controls, Siemens PLCs, instrumentation, and automation systems that are mission-critical to production. The engineer will lead troubleshooting, continuous improvement initiatives, and capital projects to ensure uptime, reliability, and compliance.
Maintain and improve performance of mission-critical equipment (E-Beam/LFE systems, tension control systems, winder/rewinders, slurry mixing, coating, weighing systems).
Develop and propose continuous improvement (CI) initiatives to increase uptime, MTBF, and equipment reliability.
Lead CAPEX projects, including planning and execution of equipment upgrades and installations.
Troubleshoot electrical controls, instrumentation, and automation issues in real-time manufacturing environments.
Train, mentor, and support maintenance supervisors and technicians, including PM/TPM scheduling and troubleshooting guidance.
Support spare parts management, including sourcing, stocking, and control of critical components.
Write and document preventive maintenance, calibration procedures, and training materials, particularly for commissioning activities.
Serve as liaison between IT and plant operations for network and automation connectivity issues.
Provide flexible support, including occasional weekends and on-call coverage.
Bachelor’s Degree in Electrical or Electronic Engineering.
Proficiency with AutoCAD and MS Office.
Experience with instrumentation and industrial automation in high-volume, fast-paced manufacturing environments.
Knowledge of lean manufacturing techniques and structured quality systems.
Strong experience with Siemens PLCs (programming, troubleshooting, tuning AC/DC/VFD servo motor drives, single/multi-loop controllers).
Proficiency in ladder logic, P&ID diagrams, and automation systems for motors, pumps, load cells, temperature, pressure, and level controllers.
Hands-on experience in extrusion, injection molding, or web-handling/transport systems.
Ability to read and interpret loop drawings, P&IDs, schematics, wiring diagrams, and mechanical prints.
HMI programming skills: WinCC, Wonderware, or similar systems.
PLC experience: Siemens (required), Automation Direct, Allen-Bradley, Mitsubishi.
Knowledge of industrial networking protocols (ProfiNet, Ethernet/IP, DeviceNet, TCP/IP).
Strong documentation skills for maintenance and calibration procedures.
Ability to work in a flexible environment with on-call responsibilities.