Lexington Controls & Automation Engineer

The Controls & Automation Engineer is responsible for the design, implementation, maintenance, and continuous improvement of manufacturing automation and control systems across the plant. This position serves as the technical owner of PLCs, HMIs, SCADA systems, industrial networks, data collection systems, and automation projects, while supporting daily manufacturing operations and long-term capital initiatives.
The Controls & Automation Engineer works closely with Operations Engineering, Engineering Technicians, Maintenance, Production, Quality, and Project Engineering to improve equipment reliability, increase process capability, reduce downtime, improve manufacturing performance, and drive digital transformation initiatives.
Key ResponsibilitiesAutomation & Controls
Develop, maintain, and troubleshoot PLC programs and control systems.
Support and improve HMI and SCADA applications.
Diagnose and resolve electrical, instrumentation, and controls-related issues.
Maintain control system documentation, backups, and change management records.
Develop and enforce controls standards across manufacturing equipment.
Support machine startups, commissioning, and process validation activities.
Maintain alarm management and machine fault diagnostics.
Manufacturing Support
Provide advanced controls support for production escalations.
Work with engineering technicians to identify and resolve recurring equipment issues.
Improve equipment uptime through root cause analysis and corrective actions.
Support preventive and predictive maintenance strategies.
Assist with troubleshooting drives, motors, sensors, vision systems, and servo controls.
Data & Process Analytics
Develop manufacturing dashboards and reporting tools.
Utilize process data to identify opportunities for scrap reduction, yield improvement, and downtime reduction.
Support SPC initiatives and process monitoring systems.
Analyze process trends and provide recommendations for continuous improvement.
Develop automated data collection and reporting solutions.
Project Engineering
Lead controls-related capital projects from concept through implementation.
Develop project scopes, schedules, budgets, and technical specifications.
Manage controls vendors, system integrators, and contractors.
Support FAT, SAT, commissioning, and startup activities.
Provide technical input during equipment procurement and design reviews.
Process Capability & Continuous Improvement
Support process capability studies (Cp, Cpk, Pp, Ppk).
Assist with GR&R and Measurement System Analysis activities.
Support DOE and Six Sigma improvement projects.
Develop automated systems for monitoring critical process parameters.
Partner with process engineers to reduce variation and improve manufacturing capability.
Preferred QualificationsEducation
Bachelor's Degree in:
Electrical Engineering
Controls Engineering
Automation Engineering
Mechatronics Engineering
Or related engineering discipline
Required Experience
3-7+ years of manufacturing controls and automation experience.
Experience supporting high-speed manufacturing processes preferred.
Experience leading automation or capital projects preferred.
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Prysmian, as an Equal Opportunity Employer, aims to attract and recruit individuals with diverse backgrounds, skills, and abilities. We strongly believe that diversity brings significant value at all levels of the organization, increasing the possibility of capturing market opportunities and maximizing value for our customers and stakeholders. With Diversity, Equity, and Inclusion (DE&I) as part of our Social Ambition 2030 and a strategic pillar of our Company culture, Prysmian is committed to the development of an organization that prioritizes talent, where people feel respected, included, and free to fully express their potential just as they are.
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