Controls Engineer

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. 

This role begins in Durham, NC and is expected to move to Benson, NC upon completion of new facility.

Responsibilities 

• Lead hands-on programming, debugging, and commissioning of Siemens and Allen Bradley/Rockwell PLCs and HMIs for new and existing automation equipment. 
• 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. 
• Execute the scaling-equipment design-review campaign, converting findings into hardened, detailed technical deliverables for OEM vendors. 
• 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. 
• as-tested code, configuration baselines, punch closure evidence, and commissioning records. 
• 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. 
• Drive 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. 
• Configure and maintain communications between PLCs/HMIs and higher level systems (MES/SCADA). Develop and troubleshoot SCADA tags, transactions, alarming, and data acquisition as required.