Controls Engineer

• Role: Controls Engineer
• Visa: Any visa will work
• Location: Weirton, WV – 5 days onsite
  
  

About is a U.S. technology and manufacturing company that is developing and commercializing cost-effective multi-day energy storage systems to enable the global electricity system to run on 100% low-cost renewable energy, every day of the year. Driven by Form’s core values of humanity, excellence, and creativity, our team is deeply motivated and inspired to create a better world. We seek to transform the energy landscape and do our part in making the world better for all. We are supported by leading investors who share a common belief that low-cost, multi-day energy storage will be a key enabler of tomorrow’s zero carbon electric system.

Role Description:We are looking for an experienced Controls Engineer to join the Operations Team. In this role, you will be the technical backbone of our manufacturing operations, responsible for the stability, maintenance, and continuous improvement of the novel equipment used to manufacture Form Energy’s Iron-Air battery.Reporting to the Sustaining Controls Engineering Associate Manager, you will serve as the primary engineering escalation point for our Sustaining Automation Technicians. You will own the lifecycle of deployed systems, diagnosing complex controls and electrical issues, driving root-cause analysis, and independently executing PLC, HMI, and MES software improvements. You will work closely with both the Operations teams and the Manufacturing Control and Execution Systems teams to ensure maximum equipment uptime, throughput, and safety at Form Factory 1

• What You’ll Do:
• Production Escalation & Support: Serve as the primary engineering escalation point for Sustaining Automation Technicians to resolve complex electrical, controls, and OT network issues.
• Continuous Improvement: Independently identify, design, and execute PLC, HMI, and SCADA software changes to optimize existing equipment, improve throughput, and eliminate recurring downtime events.
• Systems Integration & Troubleshooting: Troubleshoot and optimize MES data transactions within PLC programs, ensuring accurate product tracking and data handshakes.
• Mentorship: Provide technical guidance, training, and mentorship to Automation Technicians on the factory floor.
• On-Call Rotation: Participate in rotating on-call responsibilities for off-hour escalations from the Automation Technicians at the factory.
• Vendor & Project Management: Work directly with equipment vendors and internal teams on equipment retrofits, upgrades, and resolving long-term technical debt.
• Safety & Compliance: Ensure all plant automated equipment functions safely and correctly, strictly following Safety and Environmental policies.
  
  

What You’ll Bring

• Experience: 6+ years of hands-on experience as an engineer working on industrial control systems in a manufacturing environment.
• Communication: Strong technical communication skills, both written and verbal, with the ability to translate complex engineering issues for operations teams.
• PLC Programming and Troubleshooting
• Siemens TIA-Portal (Required, execute independently)
• Rockwell Studio 5000 (Required, execute independently)
• Beckhoff TwinCat (Nice to Have)
• SCADA/HMI Systems
• Ignition Perspective (Required, with minimal supervision)
• Siemens WinCC & Rockwell FTView ME (Required, with minimal supervision)
• Robotics & Vision (Troubleshooting Focus)
• FANUC, Epson, Kawasaki (Nice to Have)
• Keyence and Cognex Barcode Scanners & Inspection (Required, basic knowledge/troubleshooting)
• MES Integration
• PLC Product Tracking & Handshake/Data Programming (Required, execute independently)
• Ignition Integration for Data (Required, with minimal supervision)
• Electrical & Safety
• Review/Redline/Read Electrical Schematics (Required, execute independently)
• Siemens ProfiSafe, Rockwell CIP Safety, and Hardwired Safety Systems (Required, execute independently)
• OT Network & Data
• Configure & Troubleshoot Managed Network Switches (Required, execute independently)
• iba & Octoplant (Required, execute independently)
• Problem-solving: Exceptional attention to detail in root-cause analysis, testing, and documenting procedures.
• Education: Bachelor's Degree in Electrical/Controls/Mechatronics Engineering or equivalent practical experience.
  

If you’re open to exploring the opportunity, I’d be happy to share more details and discuss the role with you.

Skills: controls engineer,operations,manufacturing,form,integration,mechanical assemblies,troubleshooting