Sr. Controls Engineer

Vulcan Elements is manufacturing American rare-earth permanent magnets for a secure, resilient future. With a focus on national security and economic resiliency, we serve critical industries such as defense, aerospace, and automotive powering a high-technology future. Vulcan Elements is building a team of ambitious professionals committed to Mission Focus, Technical Excellence, and Transparency. 

As the Sr. Controls Engineer (FAT/CSV) you will lead automation acceptance and commissioning for a massive 1 million square foot manufacturing facility expansion. You will own the automation acceptance thread across a large OEM equipment campaign - authoring standardized FAT/SAT protocols, running the program-wide punch register; writing, modifying, and troubleshooting PLC code from punch-item fixes through commissioning and a share of live controls support. This is a high-impact, high-ownership role requiring deep technical expertise in industrial automation. Domestic and international travel to OEM facilities up to ~50% during test campaigns. 

This role begins in Durham, NC and is expected to move to Benson, NC upon completion of new facility.

Responsibilities 

• Lead hands-on programming, debugging, and commissioning of Siemens and Allen Bradley/Rockwell PLCs and HMIs for new and existing automation equipment. 
• Develop, modify, and maintain PLC code structures, HMI screens, safety circuits, device mapping, and networking configurations to ensure robust and standardized automation performance across all equipment. 
• Execute the scaling-equipment design-review campaign, converting findings into hardened, detailed technical deliverables for OEM vendors. 
• Review vendor electrical schematics, controls architectures, and PLC/HMI logic. Own the FAT/SAT campaign: author standardized acceptance protocols, covering PLC logic conformance, HMI/alarm acceptance, interlock validation, and network/security verification. Run the program-wide punch list and coordinate witness assignments. 
• as-tested code, configuration baselines, punch closure evidence, and commissioning records. 
• Integrate with Quality’s validation system - protocols live in Quality’s framework and carry Quality’s approval; you author the automation content and align with Manufacturing Engineering’s master schedule and process acceptance criteria. 
• Drive the integration and commissioning of robotics, vision systems, AGVs, conveyors, and motion control systems—including servos and VFDs—to enable seamless material flow and high reliability production operations. 
• Configure and maintain communications between PLCs/HMIs and higher level systems (MES/SCADA). Develop and troubleshoot SCADA tags, transactions, alarming, and data acquisition as required. 
• Serve as a senior-level escalation point for diagnosing complex automation issues involving networks, motion systems, instrumentation, and industrial communication protocols. 

Deliverables You Will Develop, Review, or Support 

• PLC code architecture, HMI screens, vision inspection programs, tag databases, MES/SCADA transaction lists, network IP lists, password inventories, and system backups. As-tested PLC code baselines, configuration backups, and acceptance evidence packages. 
• Controls risk assessments, interlock/guarding logic, and safety rated PFMEA inputs. 
• Controls layouts, network topology layouts, station cycle times, sequence diagrams, and automation simulations. 
• Electrical schematics, pneumatic drawings, controls panel layouts, and industrial network architecture. 
• FAT/SAT protocols, the program punch list, I/O checkout records, and handover packages. 

Responsibilities and tasks outlined are not exhaustive and may change as determined by the needs of the business 

Qualifications 

• Bachelor’s or Master's degree in electrical engineering, Automation Engineering, Mechatronics, or related field with 7+ years of direct industrial automation and controls engineering experience. 
• Strong hands-on experience programming and commissioning Siemens and Allen Bradley/Rockwell PLCs and HMIs. 
• Demonstrated multi-vendor acceptance campaign management, disciplined change control with the ability to triage punch items to fix in situ or kick back to a vendor. Technical writing that vendors and auditors can both execute against. 
• Deep understanding of servos, VFDs, highspeed conveyors, robotic cells, and automated material handling systems. 
• Proficiency with Ethernet/IP, Profinet, EtherCAT, OPCUA, Modbus, serial, and similar industrial communication standards. 

Must be a U.S. Person due to required access to U.S. export-controlled information or facilities

Preferred Skills

• Background as a commissioning-focused controls engineer at a system integrator or machine OEM - someone who has both written machine code and accepted other people’s. 
• Robotics & Vision Systems: Working experience with multi axis robotic systems (Fanuc, Kuka, ABB) and machine vision platforms (Cognex, Keyence) 
• Experience in heavy industrial, greenfield, chemical, or metallurgical manufacturing environments. 
• Experience developing SCADA applications in Ignition, FactoryTalk, Wonderware, or similar platforms. 
• AGV integration experience 
• Familiarity with Python, C++, or other high-level languages for automation or data analytics. 
• Experience in regulated industries or such as Defense, Aerospace, or Automotive or GAMP 5 / computer system validation exposure 

Physical and Environmental Requirements

The position requires regular presence on the production floor and the ability to navigate all areas of the facility. Candidates must be able to climb stairs, stand and walk for extended periods, and work in environments that may be hot, humid, or noisy. The role also requires the use of personal protective equipment, including respirators, and adherence to all applicable safety policies, procedures, and regulatory requirements. Employees must be able to complete required fit testing, wear appropriate PPE for the duration of assigned tasks, and respond safely to changing conditions within the production environment.