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 .
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