1. Role Overview The Controls Engineer is responsible for the design, development, testing, commissioning, deployment and lifecycle support of PLC-based industrial automation systems. The role encompasses PLC software development, control system architecture,motion control, industrial networking, HMI/SCADA integration, electrical controls, system commissioning, troubleshooting and customer support for crane automation, transfer car automation, material handling systems and other industrial automation projects.

2. Key Responsibilities

PLC Software Development

- Develop PLC software using IEC 61131-3 languages (ST, LD, FBD and SFC where applicable).
- Develop modular software using FBs, FCs, DBs, UDTs and reusable libraries.
- Configure PLC hardware, remote I/O and distributed control architectures.
- Develop and optimize machine sequences, positioning and motion control applications.
- Perform software simulation, testing and debugging.

System Integration

- Integrate PLCs with HMI/SCADA, drives, sensors, remote I/O and third-party equipment.
- Configure and troubleshoot PROFINET, PROFIBUS, Ethernet/IP, Modbus TCP/IP and OPC UA.
- Configure Industrial LAN/WLAN infrastructure.

Commissioning & Site Activities

- Lead FAT, SAT and on-site commissioning.
- Tune positioning, drive and motion parameters.
- Troubleshoot PLC, communication, electrical and field device issues.
- Support customer acceptance and system handover.

Electrical Controls

- Interpret electrical schematics and control drawings.
- Support VFDs, MCCs, switchgear and field wiring verification.
- Validate machine safety interlocks and electrical commissioning.

Documentation & Leadership
- Prepare FDS, SDS, I/O lists,



commissioning reports and software backups.
- Maintain software version control and technical documentation.
- Mentor junior engineers and coordinate with customers, contractors and project teams.

3. Required Technical Skills

PLC Platforms: Siemens TIA Portal, STEP7, S7-1200, S7-1500

Programming: Structured Text (ST), Ladder Diagram (LD), Function Block Diagram (FBD), Sequential Function Chart (SFC)

Motion Control: Absolute/Relative Positioning, Encoder Feedback, VFD Applications

Industrial Communication: PROFINET, PROFIBUS, Ethernet/IP, Modbus TCP/IP, OPC UA

Automation: Crane Automation, Transfer Cars, Material Handling Systems, Safety PLCs

Electrical: Control Panels, MCCs, Motor Control, Instrumentation, Electrical Commissioning

HMI/SCADA: WinCC and similar HMI/SCADA platforms

4. Qualifications

- Bachelor's Degree in Electrical, Electrical & Electronics, Instrumentation or Automation

Engineering.
- Industrial Automation certification is an advantage.

5. Experience

- 812 years of industrial automation experience.
- Minimum 7 years of hands-on PLC programming.
- Experience in software development, commissioning and troubleshooting of PLC-based automation systems.
- Experience in crane automation, transfer cars or material handling systems is highly desirable.
- Experience leading multidisciplinary engineering and commissioning teams.

6. Preferred Skills

- Functional Safety (SIL/PL) and Safety PLC programming.
- PLC migration projects and reusable software architecture.
- Version control and software lifecycle management.
- Industrial Cybersecurity awareness.
- Robust analytical, communication and customer-facing skills.

📌 Control Engineer (Mumbai)
🏢 EMeasurematics
📍 Mumbai