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*Controls Systems Engineer / Electrical Automation Engineer* Position Summary

Apel Extrusions is seeking a highly motivated and hands‑on Controls Systems Engineer to support, maintain, and improve the automation, electrical controls, industrial networking, and manufacturing information systems throughout our aluminum extrusion operations. This position plays a critical role in maximizing equipment reliability, minimizing downtime, and implementing continuous improvement initiatives across the facility.

The Controls Systems Engineer will work closely with Operations, Maintenance, Engineering, IT, contractors, and OEMs to troubleshoot complex manufacturing equipment issues, develop engineering solutions, and lead automation projects from concept through commissioning. This role requires strong technical expertise in PLCs, HMIs, drives, SCADA systems, industrial networking, and manufacturing systems integration, as well as a willingness to actively engage on the production floor diagnosing and resolving equipment issues.

This is a plant‑based position requiring frequent presence in a non‑temperature‑controlled manufacturing environment, active participation in troubleshooting activities, and direct interaction with operating and maintenance personnel.

Primary Responsibilities

• Design, program, troubleshoot, modify, and maintain:
  • Allen‑Bradley ControlLogix and CompactLogix PLCs
  • Allen‑Bradley PowerFlex Variable Frequency Drives (VFDs)
  • Allen‑Bradley PanelView HMIs
  • Servo systems, motion controls, and associated automation equipment
  • Industrial Ethernet communication networks
• Modify PLC and HMI programs to improve equipment reliability and functionality.
• Implement machine safety logic, interlocks, and control strategies.
• Diagnose and resolve electrical, controls, instrumentation, communications, and automation faults.
• Support installation, startup, commissioning, and validation of new equipment and control systems.
• Develop and maintain standardized programming practices, electrical documentation, and control narratives.
• Maintain backups and revision control of PLC, HMI, SCADA, and drive programs.

SCADA & Manufacturing Systems

• Develop, maintain, and improve Ignition applications.
• Configure user security and role‑based access controls.
• Develop scripting and automation within Ignition.
• Support manufacturing data acquisition and visualization initiatives.
• Troubleshoot data collection, historian performance, and system integration issues.

SQL & ERP Integration

• Maintain SQL databases supporting manufacturing operations.
• Develop SQL queries, stored procedures, reports, and data analytics tools.
• Interface production equipment with SQL‑based ERP and business systems.
• Support manufacturing KPI reporting, production analytics, and operational decision‑making.
• Troubleshoot data integrity and communication issues between manufacturing equipment and enterprise systems.
• Support industrial automation networks integrated with the corporate IT infrastructure utilizing dedicated VLANs.
• Configure, maintain, and troubleshoot:
  • Managed Ethernet switches
  • Ethernet/IP communications
  • Industrial network devices
  • VLAN communications
  • Network reliability and performance
• Coordinate with Corporate IT regarding cybersecurity, firewall configurations, network architecture, and system updates.

Maintenance & Operations Support

• Actively participate in troubleshooting and resolving equipment failures alongside maintenance technicians, engineers, and operations personnel.
• Lead root cause investigations for recurring equipment and process issues.
• Develop corrective actions and long‑term solutions to eliminate repetitive failures.
• Create preventive and predictive maintenance strategies for automation and controls systems.
• Track equipment downtime, failure frequencies, and reliability metrics.
• Provide technical training and mentorship to maintenance personnel and electrical trades.

Engineering & Continuous Improvement

• Lead controls modernization, automation upgrades, and continuous improvement projects.
• Evaluate obsolete hardware and develop replacement and migration strategies.
• Support capital projects from concept development through commissioning and startup.
• Review and participate in equipment modifications and capital installations while ensuring compliance with applicable engineering standards.
• Facilitate risk assessments, value analyses, and engineering studies to support repair, replacement, or redesign decisions.
• Manage contractor and OEM activities during equipment repairs, upgrades, and installations.
• Develop engineering solutions that improve safety, reliability, productivity, quality, and operational efficiency.

Required Qualifications

• Bachelor's degree in Electrical Engineering, Controls Engineering, Computer Engineering, or related engineering discipline; or
• Licensed Journeyman Electrician with advanced PLC/Automation certification and equivalent industrial experience.
• Minimum 5 years of industrial automation and controls experience in a manufacturing environment.
• Experience programming Allen‑Bradley PLC platforms, including ControlLogix and CompactLogix.
• Experience with Allen‑Bradley PowerFlex drives.
• Experience developing and troubleshooting HMI systems.
• Experience with Ignition SCADA.
• Strong SQL database knowledge and development experience.
• Experience integrating manufacturing equipment with ERP and manufacturing systems.
• Knowledge of Ethernet/IP and industrial networking systems.
• Strong electrical and controls troubleshooting skills.
• Excellent communication, organizational, and project management skills.

Preferred Qualifications

• Experience in aluminum extrusion, metals manufacturing, or other continuous manufacturing operations.
• Experience with Rockwell Studio 5000.
• Experience with FactoryTalk products.
• Experience with OPC UA communications.
• Knowledge of industrial cybersecurity best practices.
• Experience with SQL Server Reporting Services (SSRS), Microsoft Power BI, and Microsoft Fabric.
• Understanding of ISA‑95 manufacturing architecture.

This position is primarily plant‑based within a heavy industrial manufacturing environment. The Controls Systems Engineer is expected to maintain a significant presence on the production floor and actively engage with maintenance, operations, and engineering personnel to troubleshoot equipment and implement improvements.

Requirements include:

• Physical interaction with machinery for troubleshooting, testing, commissioning, and maintenance support.
• Participation in planned maintenance outages, equipment startups, and capital project installations.
• Occasional after‑hours, weekend, or emergency support as required to maintain critical production equipment.
• Strict adherence to all company and regulatory safety procedures.

Ideal Candidate Profile

The successful candidate is a hands‑on manufacturing automation professional who is equally comfortable troubleshooting equipment on the production floor, developing PLC and SCADA applications, analyzing manufacturing data, supporting industrial networks, and leading engineering improvement projects. They thrive in a fast‑paced manufacturing environment, enjoy solving complex problems, and possess a strong commitment to safety, reliability, operational excellence, and continuous improvement.