Posted 5 months ago

PLC Programmer/Controls and Power Systems Engineer

ArlingtonOn-siteFull-time

AI Summary

Controls and PLC engineer focused on modifying and troubleshooting Siemens-based PLC logic for thin-film manufacturing equipment, with responsibility for safety interlocks, HMI enhancements, and roll-to-roll process control.

About this role

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The PLC Programmer/Controls and Power Systems Engineer is responsible for modifying, troubleshooting, and improving control systems on thin-film manufacturing equipment, with a strong focus on Siemens PLC–based systems.

This role supports both Original Equipment Manufacturer built production machines and a unique developed roll-to-roll (R2R) machine, working closely with equipment manufacturers, process engineers, and production teams to improve reliability, safety, throughput, closed loop system feedback and functionality.

What you'll be doing:

Modify, debug, and optimize PLC programs on existing production equipment, primarily Siemens-based systems, but not limited to Siemens.

Work directly with equipment manufacturers (OEMs) to implement fixes, upgrades, and functional improvements.

Support commissioning, re-commissioning, and acceptance of modified machines.

Improve machine reliability, uptime, and process stability through control system enhancements.

Develop and improve PLC logic for a unique R2R machine, with no OEM, including new features and performance improvements.

Implement and maintain machine safety logic, interlocks, and alarms.

Troubleshoot electrical, sensor, actuator, and communication issues impacting machine operation.

Collaborate with process and equipment engineers to translate process needs into control logic.

Support integration of motion control, web handling, heaters, pumps, vacuum systems, and power supplies.

Work with HMI improvements for usability, diagnostics, and operator feedback.

Ensure that machine subsystems receive power within defined electrical and operational requirements (voltage, current, sequencing, protection).

Maintain PLC documentation, version control, and change records.

Support production during ramp-up and troubleshooting events.

What you will bring to this role:

BS or technical degree in Electrical Engineering, Automation, Mechatronics, or related field.

Minimum 5 years of experience working with PLCs in an industrial environment.

Strong hands-on experience modifying and troubleshooting existing PLC code (not only new development).

Experience working with OEM equipment and external machine vendors.

Knowledge of industrial communication protocols (PROFINET, PROFIBUS, Ethernet/IP).

Experience with motion control, drives, sensors, and industrial I/O.

Ability to read and understand electrical schematics.

Comfortable working in a manufacturing environment and supporting live production equipment.

Extra points for the following:

Experience with roll-to-roll (R2R) or web-handling equipment.

Background in thin-film PV, semiconductor, display, or vacuum-based manufacturing.

Experience with Siemens TIA Portal, HMI, and safety PLCs.

Familiarity with vacuum systems, heaters, pumps, mass-flow controllers, or power supplies.

Experience improving legacy control systems or reverse-engineering OEM logic.

Understanding of machine safety standards (e.g., interlocks, E-stops, safety relays/PLCs).

Skills

ActuatorsChange ManagementDocumentationElectrical SchematicsEthernet/IPHeatersHMIIndustrial NetworkingI/O WiringMass Flow ControllersMotion ControlProcess AutomationProfibusProfinetPumpsRoll-to-roll EquipmentSensorsSiemens PLCsSiemens TIA PortalSIL/safety LogicVacuum SystemsVersion ControlVFDs/drivesWeb Handling