Lead Automation Engineer Visa Sponsorship Jobs in Illinois

REPORTS TO

Electrical & Automation Engineering Manager

COMPENSATION

Salary Range: $125,000 to $135,000 base annually, depending on experience.

JOB SUMMARY

The Automation Engineer III is a senior individual contributor who owns machine control software end to end for Serac filling, capping, and cup-filling systems. The engineer is responsible for control architecture, PLC and HMI development, motion and servo strategy, machine safety implementation, and customer-site commissioning on complex capital equipment. This role carries deep machine expertise rather than supervisory responsibility, and is expected to resolve the problems that stop a machine when no one else can. Direct experience with cup filling and form-fill-seal equipment is strongly preferred.

ESSENTIAL FUNCTIONS

• Own control system design and software development for assigned machines and projects, including control architecture, I/O strategy, network topology, and Rockwell Studio 5000 / ControlLogix program structure using reusable Add-On Instructions and User-Defined Types.
• Develop and optimize servo and multi-axis motion for indexing, filling, sealing, and lidding operations, including cam profiling, electronic gearing, registration correction, and cycle-time tuning on high-speed machinery.
• Develop FactoryTalk View SE/ME operator interfaces covering recipe management, changeover, alarm and diagnostic strategy, production counters, and guided fault recovery.
• Lead Factory Acceptance Testing and Site Acceptance Testing: author protocols, run the test, drive punch-list closure, and secure customer sign-off.
• Lead field commissioning, startup, and production ramp-up at customer sites in North America and internationally, including operator and maintenance training and formal handover.
• Serve as senior technical escalation for machine faults in the field, tracing PLC logic, live I/O, servo and drive behavior, interlocks, permissives, and industrial network diagnostics to root cause.
• Specify and implement machine safety systems to ISO 13849, IEC 60204-1, and NFPA 79, including safety PLC logic, guarding interfaces, light curtains, and validated recovery sequences.
• Partner with mechanical engineering, electrical design, assembly, and R&D during machine development, prototype trials, and continuous improvement initiatives.
• Establish and maintain Serac programming standards, reusable code libraries, naming conventions, version control, and as-built documentation.
• Mentor Automation Engineer I and II staff on programming practice, commissioning workflow, and field troubleshooting discipline.
• Performs other duties as assigned.

REQUIRED KNOWLEDGE, SKILLS, AND ABILITIES

• Expert-level Rockwell Studio 5000 / ControlLogix and CompactLogix programming in ladder logic and structured text, including Add-On Instructions, User-Defined Types, and modular state-based machine code.
• Demonstrated servo and motion control capability: Kinetix drives, axis configuration, homing, cam profiles, electronic gearing, registration, and high-speed synchronization.
• Hands-on experience with cup filling, tub filling, or form-fill-seal machinery, including cup denesting and indexing, dosing and filling valves, film or lid sealing, date and lot coding, and reject handling. Equivalent rotary or inline filling and capping experience will be considered.
• FactoryTalk View SE/ME HMI development, including recipe handling, alarm rationalization, and diagnostic screens. Siemens TIA Portal and WinCC are accepted as secondary platforms.
• Working command of industrial networks: EtherNet/IP, device-level diagnostics, managed switch configuration, remote I/O, and PLC-to-enterprise data exchange.
• Applied knowledge of machine safety and electrical standards, including ISO 13849, IEC 60204-1, NFPA 79, and UL 508A; able to specify a safety architecture and defend it to a customer.
• Fluent reading of electrical schematics, control panel drawings, I/O lists, P&IDs, and pneumatic diagrams, and able to redline them accurately.
• Proven ability to work independently at customer sites under production pressure, representing Serac to plant engineering, maintenance, and operations personnel.
• Clear written and verbal communication, with documentation discipline strong enough that the next engineer can pick up the machine without a phone call.
• Experience with hygienic, sanitary, CIP/SIP, aseptic, or extended-shelf-life filling environments is an advantage.

EDUCATION AND EXPERIENCE

• Bachelor's degree in Electrical Engineering, Mechatronics Engineering, or a closely related engineering discipline. Equivalent demonstrated experience will be considered for candidates with deep machine-build background.
• Seven or more years of automation and controls experience, the majority of it at an OEM machine builder, equipment manufacturer, or systems integrator.
• Direct experience programming and commissioning cup fillers, tub fillers, or form-fill-seal machines is strongly preferred.
• Demonstrated ownership of machines or subsystems from control design through FAT, SAT, and customer startup.
• Experience in dairy, food, beverage, personal care, or household-products packaging applications is preferred.
• Must be able to travel domestically and internationally, estimated at 30 to 50 percent depending on project phase, with a valid passport or the ability to obtain one.

PHYSICAL DEMANDS

Work is performed largely in an office or climate-controlled warehouse environment. Some hours will be spent at various remote locations. Hours of work are generally during regular business. There will be some variation in work hours due to employee shift schedules, special projects, deadlines, customer needs and various other business concerns. Out of town and overnight travel, both local and international, may be required for business and education, by air and/or auto. Must be able to lift and carry up to 35 pounds, as well as the ability to bend, kneel, walk or sit for extended periods of time. The ability to reach above head and below knees is also required.

This job description describes the general nature and level of work performed by the employee assigned to this position. It does not state or imply that these are the only duties and responsibilities assigned to the job. The employee may be required to perform other job-related duties as requested. All requirements and duties are subject to change over time.