Sr Controls Engineer

EnerSys is a global leader in stored energy solutions for industrial applications. We have over thirty manufacturing and assembly plants worldwide servicing over 10,000 customers in more than 100 countries. Worldwide headquarters are located in Reading, PA, USA with regional headquarters in Europe and Asia. We complement our extensive line of Motive Power and Energy Systems with a full range of integrated services and systems. With sales and service locations throughout the world, and over 100 years of battery experience, EnerSys is the power/full solution for stored DC power products.

Motive Power applications include industrial lift trucks and pallet jacks, rail equipment, mining equipment, and airline ground support equipment. Some of the motive power brands include Hawker, Ironclad, General Battery, and Fiamm. Wherever there is a need for motive power, EnerSys offers the perfect energy solution.

 

Job Purpose

The Senior Controls Engineer at the Springfield facility is responsible for sustaining, optimizing, and advancing the performance of manufacturing equipment and automation systems. This position oversees plant-wide controls projects, delivers daily technical support to both operations and maintenance teams, and drives continuous improvement initiatives aimed at enhancing safety, reliability, and productivity. The position works closely with manufacturing, maintenance, quality, safety, production and engineering teams while managing project scope, cost, and schedule.

Essential Duties and Responsibilities

· Lead and execute plant-wide controls and automation projects, including project justification, ROI analysis, budgeting, scheduling, and resource coordination.

· Design, develop, implement, and modify PLC, HMI, robotics, vision, and servo control systems for automated manufacturing equipment.

· Write, maintain, and troubleshoot complex PLC programs using ladder logic and structured text.

· Provide hands-on troubleshooting and technical support for electrical, electronic, and electromechanical equipment, including PLCs, robotics, servo drives, vision systems, AC/DC drives, and automated packaging machinery.

· Coordinate control system builds, equipment installations, integration, commissioning, and operational testing.

· Maintain and update electrical schematics, control documentation, and operating instructions using AutoCAD Electrical and related tools.

· Support and lead continuous improvement initiatives focused on safety, uptime, process capability, and operational efficiency.

· Participate in daily MDI meetings and clearly communicate technical issues, root cause analyses, and corrective actions.

· Support preventative maintenance strategies and equipment reliability efforts in coordination with maintenance and operations.

· Provide technical leadership and mentorship to controls engineers, technicians, and maintenance personnel as needed.

· Ensure compliance with all EnerSys safety, environmental, and health policies, including PPE requirements, training, and monitoring programs.

Qualifications

To perform this job successfully, an individual must be able to perform each essential duty satisfactorily. The requirements listed below are representative of the knowledge, skill, and/or ability required. Reasonable accommodations may be made to enable individuals with disabilities to perform the essential functions.

Education

· Bachelor’s degree in Electrical, Electronic, or related Engineering discipline.

· Minimum of one (1) years of project-based engineering experience required.

· Five (10) or more years of controls or automation experience in a manufacturing environment preferred.

· Experience in highly automated manufacturing environments is strongly preferred; battery manufacturing experience is a plus.

· Equivalent combinations of education and experience will be considered.

   Strong experience with PLC platforms, including Allen-Bradley and Modicon; ability to develop programs from scratch.

· Advanced robotics experience, particularly Fanuc robots with IR vision-guided systems (Motoman experience a plus).

· Strong understanding of control wiring, safety circuit design, and machine safety standards.

· Working knowledge of industrial networks and communication protocols (EtherNet/IP, DeviceNet, Sercos).

· Proficiency with AutoCAD Electrical; SolidWorks experience preferred.

· Understanding of PID control, process control concepts, and automated manufacturing systems.

· Strong troubleshooting, root cause analysis, and data-driven problem-solving skills.

· Ability to manage multiple projects simultaneously in a fast-paced manufacturing environment.

· Strong written and verbal communication sk