Sr. Controls Engineer
at Vulcan Elements · 51-100 employees
Equity · $430M · Apr 2026
- Seniority
- Senior
- Location
- Research Triangle Park, NC
- Posted
- 5d ago
pythonc++
at Vulcan Elements · 51-100 employees
Vulcan Elements is a manufacturer of rare-earth magnets.
<p><span data-contrast="none">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.</span><span data-ccp-props="{"201341983":0,"335551550":6,"335551620":6,"335557856":16777215,"335559739":0,"335559740":240}"> </span></p> <p><span data-contrast="none">As the Senior Controls Engineer you will lead the controls and software integration for a massive </span><span data-contrast="none">1 million square foot manufacturing facility</span><span data-contrast="none"> expansion. You will be responsible for technical leadership of a team of controls engineers, establishing site-wide automation standards, and owning the hardware/software interface of all production and material handling equipment. This is a high-impact, high-ownership leadership role requiring deep technical expertise in industrial automation. </span><span data-contrast="none">Domestic and international travel to OEM facilities up to ~20% during test campaigns.</span><span data-ccp-props="{"201341983":0,"335551550":6,"335551620":6,"335557856":16777215,"335559739":0,"335559740":240}"> </span></p> <p><strong><span data-contrast="none">Responsibilities</span></strong><span data-ccp-props="{"201341983":0,"335551550":6,"335551620":6,"335557856":16777215,"335559739":0,"335559740":240}"> </span></p> <ul> <li><span data-contrast="none">Lead hands-on programming, debugging, and commissioning of Siemens and Allen Bradley/Rockwell PLCs and HMIs for new and existing automation equipment.</span><span data-ccp-props="{"201341983":0,"335551550":6,"335551620":6,"335557856":16777215,"335559739":0,"335559740":240}"> </span></li> <li><span data-contrast="none">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.</span><span data-ccp-props="{"201341983":0,"335551550":6,"335551620":6,"335557856":16777215,"335559739":0,"335559740":240}"> </span></li> <li><span data-contrast="none">Own and evolve the site controls standard: code architecture, state machines, alarm and HMI conventions. Author the controls specification issued with every OEM equipment package and build the templates and code libraries that let area engineers and integrators execute consistently.</span><span data-ccp-props="{"201341983":0,"335551550":6,"335551620":6,"335557856":16777215,"335559739":0,"335559740":240}"> </span></li> <li><span data-contrast="none">Own the ISA-88 physical and procedural models; execute the batch-engine placement study (PLC-resident vs. supervisory vs. MES-driven), decision, and implementation.</span><span data-ccp-props="{"201341983":0,"335551550":6,"335551620":6,"335557856":16777215,"335559739":0,"335559740":240}"> </span></li> <li><span data-contrast="none">Define safety PLC and functional safety conventions (ISO 13849 performance levels, SIL-rated loops) with EHS and equipment vendors.</span><span data-ccp-props="{"201341983":0,"335551550":6,"335551620":6,"335557856":16777215,"335559739":0,"335559740":240}"> </span></li> <li><span data-contrast="none">Support 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.</span><span data-ccp-props="{"201341983":0,"335551550":6,"335551620":6,"335557856":16777215,"335559739":0,"335559740":240}"> </span></li> <li><span data-contrast="none">Configure and maintain communications between PLCs/HMIs and higher level systems (SCADA). Own the controller-side data interface - exposed tags, handshakes, and the phase-logic contract - to the supervisory layers</span><span data-ccp-props="{"201341983":0,"335551550":6,"335551620":6,"335557856":16777215,"335559739":0,"335559740":240}"> </span></li> <li><span data-contrast="none">Review vendor electrical schematics, controls architectures, and PLC/HMI logic. Hold code review and acceptance authority for all delivered OEM PLC code. Support Factory Acceptance Tests (FATs) and Site Acceptance Tests (SATs) to ensure full compliance with functional and safety requirements.</span><span data-ccp-props="{"201341983":0,"335551550":6,"335551620":6,"335557856":16777215,"335559739":0,"335559740":240}"> </span></li> <li><span data-contrast="none">Serve as a senior-level escalation point for diagnosing complex automation issues involving networks, motion systems, instrumentation, and industrial communication protocols.</span><span data-ccp-props="{"201341983":0,"335551550":6,"335551620":6,"335557856":16777215,"335559739":0,"335559740":240}"> </span></li> <li><span data-contrast="none">Analyze OEE, downtime data, and SCADA/MES insights to identify and implement automation improvements that increase throughput, safety, and reliability.</span><span data-ccp-props="{"201341983":0,"335551550":6,"335551620":6,"335557856":16777215,"335559739":0,"335559740":240}"> </span></li> </ul> <p> </p> <ul> <li><span data-contrast="none">PLC code architecture, HMI screens, vision inspection programs, tag databases, MES/SCADA transaction lists, network IP lists, password inventories, and system backups.</span><span data-ccp-props="{"201341983":0,"335551550":6,"335551620":6,"335557856":16777215,"335559739":0,"335559740":240}"> </span></li> <li><span data-contrast="none">Controls risk assessments, interlock/guarding l