Sr. Controls Engineer (Warehouse Support)

Abbott is a global healthcare leader, creating breakthrough science to improve people’s health. We’re always looking towards the future, anticipating changes in medical science and technology.

Our diagnostic solutions are used in hospitals, laboratories, and clinics around the globe. The crucial information derived from our tests, instruments and informatics systems are often the first step in patient care decision making for hundreds of health conditions from heart attacks to blood disorders to infectious diseases and cancers.

At Abbott, you can do work that matters, grow, and learn, care for yourself and family, be your true self and live a full life. You’ll also have access to:

• Career development with an international company where you can grow the career you dream of.
• Employees can qualify for free medical coverage in our Health Investment Plan (HIP) PPO medical plan in the next calendar year.
• An excellent retirement savings plan with high employer contribution
• Tuition reimbursement, the Freedom 2 Save student debt program and FreeU education benefit - an affordable and convenient path to getting a bachelor’s degree.
• A company recognized as a great place to work in dozens of countries around the world and named one of the most admired companies in the world by Fortune.
• A company that is recognized as one of the best big companies to work for as well as a best place to work for diversity, working mothers, female executives, and scientists.

• This is not a remote opportunity
• Traveling up to 5%
• Relocation assistance is not authorized for this position.

This position works out of our Abbott Distribution Center (North Chicago), IL location in the Core Diagnostics Division.

The Warehouse PLC / Controls Engineer is responsible for maintaining, troubleshooting, and improving automated control systems within a warehouse or distribution environment. This role focuses on maximizing system uptime through rapid issue resolution, preventive maintenance, and continuous improvement of PLC-controlled equipment such as conveyors, sortation systems, and automated material handling systems.

• Diagnose and resolve Programmable Logic Control (PLC), Human machine interface (HMI), and control system issues impacting warehouse operations.
• Provide real-time support to operations teams to minimize downtime.
• Analyze system faults, alarms, and logs to identify root causes and implement corrective actions.
• Support troubleshooting of automation systems including conveyors, sorters, pick by light and robotics systems.

• Develop and maintain accurate as-built documentation for PLC programs, network architecture, and control systems.
• Update electrical schematics, I/O lists, and system configurations as modifications occur.
• Ensure documentation is organized, version-controlled, and easily accessible.

• Create and continuously improve standardized troubleshooting guides and procedures.
• Develop training materials and provide guidance to operators and maintenance technicians.
• Capture lessons learned from recurring issues to build robust knowledge bases.

• Identify opportunities for system improvements to enhance reliability, efficiency, and performance.
• Propose and implement equipment upgrades, control logic enhancements, and process optimizations.
• Collaborate with vendors and engineering teams on system modifications and new installations.

• Develop and execute preventive maintenance strategies for PLCs, control panels, and automation systems.
• Monitor system health and implement predictive maintenance techniques to prevent failures.
• Ensure compliance with maintenance schedules to maximize uptime and equipment lifespan.

• Support commissioning of new equipment, system upgrades, and retrofit projects.
• Conduct Factory and site acceptance testing (FAT/SAT) testing and validate system performance post-implementation.
• Verify proper operation of safety circuits and compliance with standards.

• Bachelor’s degree in engineering (Electrical or Controls Engineering preferred) or equivalent work experience.
• 4-7+ years of experience with PLC programming and troubleshooting (Prefer Allen-Bradley).
• FDA regulated manufacturing, consumer packaged goods or similar experience.
• Experience with validation or commissioning documentation.

• PLCs, HMIs, VFDs, and industrial networks (EtherNet/IP, Profibus, etc.)
• Electrical systems and control panels

• Proven ability to troubleshoot complex automation issues under time pressure.

• Prefer Experience in warehouse automation, distribution centers, or material handling systems.
• Experience with WMS and other IT/OT systems integration.
• Working knowledge of the principles of quality software engineering as described by software lifecycle development processes that are consistent with ISO, IEEE, or other FDA recognized standards.
• Programming experience using current programming languages (C#, html, SQL) and/or experience in software development.
• Be familiar with tools within Continuous Improvement (e.g., 6 Sigma, Lean, Kaizen, etc.) and participate in problem resolution.
• Ability to manage multiple tasks and know how to prioritize the workday.
• ‘Out-of-the-box’ thinking and problem solving.

• Strong analytical and problem-solving skills
• Hands-on troubleshooting expertise
• Clear technical documentation ability
• Continuous improvement mindset
• Effective communication with cross-functional teams