Controls Engineer in Barnsley

We are seeking a highly skilled and motivated Controls & Automation Engineer to join our growing and highly successful engineering team. The successful candidate will play an active role in the development of new automated machines, working alongside our mechanical and electrical design teams from concept through to production-ready systems. They will be responsible for designing, developing, and commissioning PLC-based control systems and HMI interfaces, and will provide ongoing field support including calibration visits, fault diagnosis, and troubleshooting at customer sites. This is a technically demanding role requiring broad expertise across motion control, variable frequency drives, and software development, combined with a practical hands-on approach to factory acceptance testing and customer commissioning.

KEY RESPONSIBILITIES

• Design, develop, and commission PLC programs for the control of industrial automation machinery.
• Collaborate with the mechanical and electrical engineering teams in the development of new automated machines, from concept through to production-ready control systems.
• Create and implement graphical HMI programs to complement and support PLC-based control systems.
• Select, configure, program and commission servo motor and drive systems for precision motion control applications.
• Select, configure, program and commission stepper motor and drive systems as appropriate to application requirements.
• Program and configure Variable Frequency Drives (VFDs) for the control of AC induction motors.
• Participate in factory acceptance testing (FAT) at our facility, working alongside the production and engineering teams.
• Travel to customer sites to carry out equipment start-up, commissioning, and operator/maintenance training.
• Produce clear and accurate technical documentation, including control narratives, wiring schedules, operator manuals and commissioning records.
• Provide on-site fault diagnosis and technical troubleshooting support at customer sites when required.
• Carry out calibration checks on customer premises to ensure continued accurate and reliable operation of installed systems.
• Work collaboratively with the wider engineering teams throughout the full project lifecycle.
• Contribute to continuous improvement initiatives in engineering processes and documentation standards.
• Participate in occasional overseas commissioning trips as project requirements demand.

ESSENTIAL REQUIREMENTS

Experience & Qualifications

• Minimum 5 years of hands-on, industry-based experience writing PLC programs for the automation and control of industrial machinery. Allen-Bradley and/or Siemens.
• Demonstrable experience developing HMI graphical interface programs in an industrial environment.
• Strong knowledge of motion control systems — including the selection, programming, and commissioning of servo motors and drives.
• Proven ability to programme and configure Variable Frequency Drives (VFDs) for induction motor applications.
• Experience of carrying out or supporting factory acceptance testing of automated machinery.
• Demonstrable experience of equipment commissioning and/or customer training on site.
• Proven ability to contribute to the development of new automated machines, working collaboratively across engineering disciplines from initial specification through to production sign-off.
• Experience of visiting customer sites to carry out start-up, performance verification, and/or fault diagnosis.

Personal Attributes

• Exceptional attention to detail with a commitment to producing work of the highest accuracy.
• Willingness and flexibility to visit customer sites for commissioning and training — estimated 2 to 5 days per month on average.
• A professional, customer-facing manner suitable for on-site training and support activities.
• Self-motivated and able to manage tasks independently while working effectively within a team.
• Willingness to travel occasionally overseas in support of international customer projects.

TRAVEL & SITE WORK

This role is primarily office based. However, the successful candidate must be willing and able to travel as part of their duties. Site work is expected to average between two and five days per month. Occasional domestic and international travel for commissioning activities at customer sites further afield.