Controls Engineering Manager

Controls Engineering Manager

Location: Carrollton, TX

Department: Engineering

Reports To: Director of Engineering & Maintenance

Position Summary

The Controls Engineering Manager is responsible for leading the design, implementation, maintenance, and continuous improvement of industrial automation and control systems across a high-volume aluminum manufacturing operation. This position provides both strategic leadership and hands-on technical expertise, ensuring the reliability, performance, and modernization of plant automation systems.

The ideal candidate is a recognized subject matter expert in Rockwell Automation (Allen-Bradley) technologies with extensive recent hands-on experience designing, programming, troubleshooting, and optimizing complex control systems. This individual will serve as the organization's technical authority for automation, controls, and industrial networking while leading a team of engineers and technicians to support operational excellence, safety, quality, and productivity initiatives.

Essential Responsibilities

• Lead all plant automation and controls engineering activities across manufacturing operations.
• Provide technical leadership and oversight for control system architecture, PLC programming, HMI development, industrial networking, and SCADA systems.
• Design, develop, implement, and maintain automation solutions that improve safety, efficiency, reliability, and production throughput.
• Manage controls engineering projects from concept through commissioning, including budgeting, scheduling, contractor management, and start-up support.
• Troubleshoot complex automation issues and provide rapid resolution to minimize operational downtime.
• Establish and maintain controls engineering standards, documentation, backup procedures, and cybersecurity best practices.
• Partner with Operations, Maintenance, Quality, and Engineering teams to identify and execute continuous improvement initiatives.
• Lead root cause analysis efforts for equipment failures and recurring automation issues.
• Develop long-term automation roadmaps and modernization plans for manufacturing systems and equipment.
• Support capital projects, equipment upgrades, line installations, and expansion initiatives.
• Mentor and develop controls engineers, electricians, and maintenance personnel.
• Ensure compliance with applicable electrical, safety, and industrial standards.

Rockwell Automation Expertise Requirement

This position requires extensive expertise with Allen-Bradley and Rockwell Automation systems. Candidates without significant recent hands-on experience will not be considered.

The successful candidate must:

• Possess direct, hands-on experience with Rockwell Automation systems within the last five years.
• Demonstrate expert-level proficiency in Allen-Bradley PLC programming, diagnostics, troubleshooting, and optimization.
• Be regarded as a subject matter expert in Rockwell Automation technologies and industrial control systems.
• Have a proven history of successful implementation and support of Rockwell-based automation platforms in a manufacturing environment.
• Be capable of independently leading complex controls projects from design through commissioning.

Required Technical Qualifications

Rockwell Automation / Allen-Bradley

Expert-level experience with:

• ControlLogix and CompactLogix PLC platforms
• Studio 5000 Logix Designer
• FactoryTalk View SE and ME
• FactoryTalk AssetCentre
• FactoryTalk Historian
• FactoryTalk Linx
• PanelView HMI systems
• PowerFlex drives and drive integration
• Integrated Motion Systems
• Rockwell industrial networking solutions\

Industrial Automation Systems

Strong experience with:

• SCADA systems
• HMI development and support
• Industrial Ethernet/IP networks
• VFDs and motor control systems
• Servo systems and motion control applications
• Instrumentation and process controls
• Distributed I/O systems
• Machine safety systems
• Control panel design
• Electrical power distribution systems

Manufacturing Systems

Experience supporting industrial manufacturing operations, preferably:

• Aluminum extrusion
• Aluminum casting/foundry operations
• Metals manufacturing
• Continuous processing environments
• High-speed automated production systems

Leadership Responsibilities

• Lead, mentor, and develop controls engineering personnel.
• Establish performance objectives and development plans for team members.
• Coordinate support activities across maintenance, engineering, and production teams.
• Manage relationships with automation vendors, system integrators, and contractors.
• Drive a culture of safety, accountability, innovation, and continuous improvement.

Minimum Qualifications

• Bachelor's Degree in Electrical Engineering, Controls Engineering, Automation Engineering, or related technical discipline.
• 10+ years of industrial controls and automation experience within a manufacturing environment.
• 5+ years of leadership or supervisory experience managing engineering, automation, or controls personnel.
• Extensive recent hands-on experience with Rockwell Automation systems.
• Demonstrated experience leading automation projects and equipment commissioning efforts.
• Strong troubleshooting and root cause analysis capabilities.
• Ability to provide technical leadership and strategic direction from day one.

Preferred Qualifications

• Experience within aluminum extrusion, foundry, rolling mill, or metals manufacturing operations.
• Rockwell Automation certifications or advanced training credentials.
• Experience supporting multiple facilities or large-scale manufacturing operations.
• Knowledge of ISA, NFPA, NEC, OSHA, and industrial cybersecurity standards.
• Experience with MES integration, data acquisition, and Industry 4.0 initiatives.