Sr. Controls Engineer - FAT/CVS & Commissioning

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.

Responsibilities

PLC Programming & Commissioning: Lead hands-on programming, debugging, and commissioning of Siemens and AllenBradley/Rockwell PLCs and HMIs for new and existing automation equipment. Controls Integration & Architecture: 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. Design Reviews: Execute the scaling-equipment design-review campaign, converting findings into hardened, detailed technical deliverables for OEM vendors.

Vendor Technical Support & FATs: 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.

Turnover & Baselines: Build controls turnover packages: as-tested code, configuration baselines, punch closure evidence, and commissioning records. Validation Interface: 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. Advanced Automation & System Integration: 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.

SCADA/MES Connectivity: Configure and maintain communications between PLCs/HMIs and higherlevel systems (MES/SCADA). Develop and troubleshoot SCADA tags, transactions, alarming, and data acquisition as required. Troubleshooting & Technical Escalation: 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 Controls & IT: 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. Risk & Safety: Controls risk assessments, interlock/guarding logic, and safetyrated PFMEA inputs.

Process Design: Controls layouts, network topology layouts, station cycle times, sequence diagrams, and automation simulations. Engineering Diagrams: Electrical schematics, pneumatic drawings, controls panel layouts, and industrial network architecture. Acceptance & Commissioning: FAT/SAT protocols, the program punch list, I/O checkout records, and handover packages.

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