Job Specification: Controls Engineer Special Purpose Machinery (Coventry)

Job Title: Controls Engineer
Location: Cambridge (with occasional UK and international travel for commissioning)
Employment Type: Full-time, Permanent
Department: Automation & Controls Engineering

Overview

Our client, a leading manufacturer of special purpose machinery, is seeking an experienced Controls Engineer to join their automation team. The successful candidate will play a key role in the design, development, programming, and commissioning of bespoke automated machinery used across high-tech manufacturing sectors. This position offers hands-on involvement from concept through to commissioning, with exposure to innovative technologies and complex automation challenges.

Key ResponsibilitiesDesign & Development

• Design and develop PLC, HMI, and motion control software for bespoke automation equipment.
• Create functional design specifications, control philosophies, and I/O schedules.
• Develop machine sequencing, safety logic, diagnostics, and operator interfaces.

Project Engineering

• Work closely with mechanical, electrical, and software teams to ensure seamless system integration.
• Support the full project lifecycle including concept design, build, test, and commissioning.
• Participate in FAT, SAT, and validation processes for custom-built machinery.

Commissioning & Support

• Commission machines at the Coventry facility and at customer sites (UK and occasionally overseas).
• Diagnose and resolve control system issues, ensuring reliable operation and performance.
• Provide technical support during installation, acceptance testing, and after-sales phases.

Documentation & Compliance

• Produce and maintain accurate documentation including wiring diagrams, test plans, and software backups.
• Ensure systems comply with relevant standards (e.g., IEC 61131, Machinery Directive, CE/UKCA).
• Collaborate with the safety team to support risk assessments and safety validation.

Required Skills & Experience

Technical Skills

• Proven experience programming industrial PLCs (e.g., Siemens TIA Portal, Rockwell/Allen-Bradley, Mitsubishi, Beckhoff, Omron).
• Strong understanding of motion control, servos, robotics, and mechatronic systems.
• HMI/SCADA development experience.
• Knowledge of industrial communications (EtherCAT, Profinet, Ethernet/IP, etc.).
• Ability to read and interpret electrical schematics and mechanical layouts.

Industry Experience

• Background in special purpose machinery, automation, robotics, or high-speed manufacturing equipment.
• Experience in industries such as automotive, aerospace, packaging, pharmaceuticals, or FMCG would be advantageous.

Professional Skills

• Strong problem-solving abilities with a hands-on approach to engineering challenges.
• Ability to manage workload across multiple projects.
• Strong communication and team-working skills.
• Willingness to travel for commissioning as required.

Preferred Qualifications

• Degree, HNC, or HND in Electrical Engineering, Automation, Mechatronics, or similar.
• Experience with safety PLCs and functional safety implementation (SIL/PL).
• Familiarity with CAD/ECAD tools (ePLAN, AutoCAD Electrical).
• Knowledge of robotics platforms (Fanuc, ABB, KUKA) is a plus.