Senior Controls Engineer

From a small family business to a multi-billion-dollar global company, Sonoco has been changing the face of products and packaging since 1899 — all while keeping the heart of “People Build Businesses” alive.

Our talented people are at the core of our growth, constantly reinventing the Sonoco wheel with brilliant solutions every year. Today we are a world leader in global packaging solutions with diversified operations in over 34 countries. We're extremely proud of our portfolio of brands, our achievements in sustainability and industrialization and the groundbreaking work accomplished by our people. 

Sonoco launched the Automation Team in late 2022 to provide Corporate Resources to lead and support automation projects in partnership with ISI Robotics.  Sonoco’s long term goal was to internalize the capability to design, build, integrate, and support automation solutions thus allowing Sonoco to more quickly and effectively implement solutions in its operations. 

In late 2023, Sonoco’s Machinery Manufacturing division in Hartsville, SC was assigned to the Automation Team providing machining, fabrication and assembly capabilities.  Investments were made to double the size of the Machinery Manufacturing operation in 2024.  This assimilation of talent and resources has not only equipped the Automation Team with the capability to begin internalizing automation projects, but has also provided the knowledge and skillset to begin internalizing Machinery Manufacturing control design, installation, and support which had previously been outsourced.

Reporting directly to Sonoco’s Manufacturing Automation Engineering Manager, the Senior Electrical Engineering Manager will be responsible for leading the electrical and controls group in Machinery Manufacturing’s new facility in Hartsville, SC. They will be responsible for developing the skillsets and resources to design, build, integrate, install, and support innovative controls and automation solutions for high volume, diverse manufacturing technologies which will include the design and build of proprietary solutions that will further solidify Sonoco’s position as the World’s foremost Packaging Solutions provider. 

Responsibilities

• Leadership of the Electrical, Controls, and Automation technicians to include training and development and oversight of day to day activities.
• Development and retention of talent.
• Development of process standards that will ensure consistency in the process to include a specific focus on maximizing the safety performance of all solutions.
• Manage the change management process and IP security for all elements of solutions to include, but not limited to drawings, source code, and concepts.
• Actively participate in and lead collaborative brainstorming sessions to conceptualize the simplest automation solution for complex problems.
• Design electrical systems for customized automation solutions using EPLAN.
• Provide support for and assist Automation Technicians during panel fabrication, shop testing, installation, and field support.
• Develop reliable PLC programs in the Studio5000 environment.
• Develop intuitive HMI programs.
• Integrate comprehensive alarms and messaging into PLC and HMI programs.
• Provide advanced troubleshooting for automated machinery as needed.
• Collaborate with Operations and Maintenance teams to ensure equipment is properly operated and maintained.
• Support automated data collection and reliability tracking.
• Create capital project proposals that clearly communicate the opportunity and proposed solution to Plant, Divisional, and Corporate leadership teams
• Manage automation projects including supervising in-house, contract, and OEM resources to ensure projects are completed on-time and on-budget.
• Collaborate with internal Supply Management and OEM to generate general scopes and/or detailed Performance – Statement of Work documents for new assets.
• Actively collaborate with the Business Units in the Continuous Improvement Effort: Always find a way to keep improving.

Required Skills

• Solid knowledge of all applicable safety regulations related to controls and automation solutions
• Solid understanding and experience with electrical control system design software (EPLAN preferred)
• Demonstrated leadership and development of highly skilled controls and automation technicians.
• Overseeing lean control panel fabrication process. (leveraging EPLAN Pro Panel or similar)
• PLC and HMI programming (Studio5000 for PLC and Maple Systems for HMIs preferred)
• Ignition or similar SCADA system experience is a plus.
• Solid knowledge of troubleshooting equipment problems and performing complex system tests
• Creative thinking skills
• Detail-oriented personality
• Continuous improvement mindset
• Ability to define problems, collect data, establish facts, and draw valid conclusions
• Ability to communicate and collaborate effectively with other members of the development team and Sonoco leadership.
• Operates effectively in high pressure environments.
• Hands-on

Educational Requirements

Bachelor of Science in Electrical/Controls Engineering or similar equivalent experience.

Compensation:

The annual base salary range for this role is from $126,310 to $133,740, plus an annual target bonus of 7.5% of base salary.

We are an equal opportunity employer, and we strictly prohibit and do not tolerate discrimination against employees, applicants or any other covered persons because of race, color, religion, national origin or ancestry, sex, pregnancy, sexual orientation, marital status, gender identity or expression, age, disability, genetic information, veteran status, or any legally protected characteristic.