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Form Energy is seeking an experienced Sustaining Controls Engineer to join the Operations Team at Form Factory 1 in Weirton, WV. This role is critical to the stability and continuous improvement of manufacturing operations for Form Energy's iron-air battery systems.
You will serve as the primary technical escalation point for Sustaining Automation Technicians, owning the full lifecycle of deployed control systems. Your responsibilities include diagnosing complex electrical and controls issues, driving root-cause analysis, and independently executing PLC, HMI, and MES software improvements. You'll work closely with Operations and Manufacturing Control teams to maximize equipment uptime, throughput, and safety.
Key responsibilities:
- Serve as primary engineering escalation for complex electrical, controls, and OT network issues
- Independently identify, design, and execute PLC, HMI, and SCADA software changes to optimize equipment and eliminate recurring downtime
- Troubleshoot and optimize MES data transactions within PLC programs for accurate product tracking
- Provide technical guidance and mentorship to Automation Technicians
- Participate in rotating on-call responsibilities for off-hour escalations
- Work with equipment vendors on retrofits, upgrades, and technical debt resolution
- Ensure all automated equipment functions safely and complies with Safety and Environmental policies
Required qualifications:
- 6+ years of hands-on experience with industrial control systems in manufacturing
- Strong technical communication skills, written and verbal
- PLC programming expertise: Siemens TIA-Portal and Rockwell Studio 5000 (independent execution)
- SCADA/HMI systems: Ignition Perspective, Siemens WinCC, Rockwell FTView ME (minimal supervision)
- MES integration and PLC product tracking/data programming
- Electrical schematic review and safety systems (ProfiSafe, CIP Safety, hardwired systems)
- OT network configuration and troubleshooting (managed switches)
- iba and Octoplant experience
- Basic robotics and vision troubleshooting (FANUC, Epson, Kawasaki, Keyence, Cognex)
- Bachelor's degree in Electrical/Controls/Mechatronics Engineering or equivalent practical experience
- Exceptional problem-solving and attention to detail
Form Factory 1 is a 550,000-square-foot high-volume battery production facility near Pittsburgh, PA. Relocation assistance is available. The role offers competitive salary, stock options, and comprehensive benefits.
