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Controls Engineer – Automation & Robotics Specialist

Job Title: Production Supervisor

Location: 14737 Firetower Road Conroe, Texas 77306

Employment Type: Full-Time

Company Overview

Ultra Corpotech Inc. is a rapidly growing global manufacturing company committed to innovation, precision, and quality. Headquartered in the United States, we provide world-class products and solutions across various industries. We prioritize operational excellence, safety, teamwork, and continuous improvement while fostering a culture of accountability, growth, and compliance. We are seeking a motivated and experienced Production Supervisor to oversee daily manufacturing operations and support production goals in a fast-paced environment.

Position Summary

We are seeking an experienced Controls Engineer – Automation & Robotics Specialist to design, program, integrate, troubleshoot, and continuously improve automated manufacturing equipment and robotic systems. The ideal candidate will have strong hands-on experience with ABB industrial robots, PLC programming, HMI/SCADA systems, servo/motion controls, industrial networks, sensors, and automated production equipment.

This position will work closely with Production, Engineering, Maintenance, Quality, and Safety teams to maximize equipment reliability, improve cycle time and OEE, reduce downtime, and support new equipment and product launches.

Key Responsibilities

• Design, develop, program, and maintain industrial automation and control systems.
• Program, configure, teach, and troubleshoot ABB robotic systems, including robotic welding, material handling, machine tending, and other manufacturing applications.
• Develop and troubleshoot PLC programs using Ladder Logic, Structured Text, Function Block, and other applicable programming languages.
• Support PLC platforms such as Allen-Bradley/Rockwell, Siemens, or equivalent industrial control systems.
• Develop and modify HMI and SCADA applications for machine operation, diagnostics, alarms, and production monitoring.
• Integrate robots, PLCs, HMIs, servo drives, VFDs, safety systems, sensors, actuators, vision systems, and other automated equipment.
• Troubleshoot electrical, controls, robotic, pneumatic, hydraulic, mechanical, and communication-related equipment issues.
• Perform root-cause analysis on recurring equipment failures and implement sustainable corrective actions.
• Optimize robotic paths, PLC logic, machine sequences, and cycle times to improve productivity and equipment performance.
• Support robotic welding applications, including robot programming, weld sequencing, fixture interaction, and process optimization.
• Develop and maintain electrical drawings, control schematics, I/O documentation, network architecture, and equipment documentation.
• Support installation, startup, commissioning, validation, and acceptance testing of new equipment.
• Participate in FAT/SAT, equipment qualification, PPAP, pilot production, and production-readiness activities.
• Configure and troubleshoot industrial communication networks, including EtherNet/IP, PROFINET, Modbus, DeviceNet, and similar protocols.
• Implement machine and robotic safety systems, including safety PLCs, interlocks, light curtains, safety scanners, emergency stops, and guarding.
• Ensure control systems comply with applicable OSHA, NEC, NFPA, UL, and company safety standards.
• Monitor equipment performance and support improvement of OEE, uptime, cycle time, quality, and throughput.
• Provide technical training and troubleshooting support to maintenance technicians, operators, supervisors, and engineering personnel.
• Maintain backups and version control for PLC, HMI, robot, drive, and other equipment programs.
• Support continuous improvement, automation expansion, and Industry 4.0 initiatives.

Education and Experience

• Bachelor's degree in Electrical Engineering, Controls Engineering, Automation Engineering, Mechatronics, Mechanical Engineering, or a related technical field.
• 5–10+ years of hands-on industrial controls and automation experience in a manufacturing environment preferred.
• Demonstrated experience programming and troubleshooting ABB industrial robots.
• Strong experience with PLC programming, preferably Allen-Bradley/Rockwell and/or Siemens.
• Experience with robotic welding, automated assembly, material handling, press operations, or similar manufacturing processes is highly desirable.
• Experience comissioning and troubleshooting automated manufacturing equipment.

Technical Skills

• The successful candidate should demonstrate proficiency in:
• ABB robot programming, teaching, calibration, recovery, and troubleshooting
• PLC programming and troubleshooting
• Ladder Logic and Structured Text
• HMI/SCADA development
• Servo and motion control systems
• VFD configuration and troubleshooting
• Sensors, encoders, actuators, and instrumentation
• Industrial safety circuits and safety PLCs
• Electrical schematics and control panel design
• EtherNet/IP, PROFINET, Modbus, and industrial networking
• Robotic welding and automated manufacturing processes
• Root-cause analysis and equipment reliability improvement
• AutoCAD Electrical or equivalent electrical design software
• Python, SQL, C#, or similar programming/scripting experience is beneficial

Key Performance Expectations

• Success in this position will be measured by the ability to:
• Reduce automation and equipment downtime.
• Improve equipment uptime, OEE, and production throughput.
• Maintain reliable operation of ABB robotic systems.
• Reduce recurring controls and automation failures.
• Successfully commission new equipment and automation projects.
• Improve robotic and automated process cycle times.
• Maintain accurate controls documentation and program backups.
• Provide timely technical support to Production and Maintenance.
• Develop sustainable automation solutions that improve safety, quality, productivity, and manufacturing capacity.

Preferred Candidate Profile

The ideal candidate is a hands-on Controls Engineer who is comfortable working directly on the production floor and can independently diagnose complex automation problems. The candidate should be equally capable of connecting to a PLC or ABB robot to troubleshoot programming issues, reviewing electrical drawings, diagnosing sensors and controls hardware, and working with production teams to restore equipment quickly and safely.

Strong communication, analytical thinking, urgency, teamwork, and the ability to manage multiple automation projects in a fast-paced manufacturing environment are essential.

Work Environment

• Manufacturing plant environment with exposure to production equipment, tools, dies, noise, heat, and moving machinery.
• Work may require standing, walking, bending, kneeling, lifting, and working around active production areas.
• Must follow all required safety procedures, lockout/tagout requirements, and personal protective equipment requirements.

Benefits

• Competitive salary based on experience.
• Health, dental, and vision insurance.
• Paid time off and holidays.
• Opportunities for career advancement and professional development.
• Retirement plan options 401(k).

Ultra Corpotech Inc. is an equal opportunity employer and encourages applications from all qualified individuals. We thank all applicants for their interest; however, only those selected for an interview will be contacted.