Controls Support Engineer

About the Role

As a Controls Support Engineer specializing in Baggage Handling Systems (BHS), you will serve as a mid to high-level technical expert for PLC and Low-Level Control (LLC) infrastructure of the BHS. Your primary responsibilities will encompass ensuring the reliable operation, maintenance, troubleshooting, and optimization of PLC-controlled BHS equipment and associated control systems. You will provide technical support for PLCs, field devices, safety systems, control interfaces, and control-related faults, modifications, testing, and performance issues. Supporting the Maintenance Manager, you will work towards maintaining system availability, reliability, and meeting contractual service requirements. Additionally, you will act as a focal point for PLC/control-related incidents and contribute to the continuous improvement of site-based BHS control and maintenance services.

Scope

• Deliver first-line and advanced technical support for BHS Low-Level Controls, PLC systems, remote I/O, industrial networks, drives, scanners, sensors, and associated field equipment.
• Diagnose, analyze, and restore PLC/control incidents that impact BHS operations.
• Provide technical support for preventive, corrective, breakdown, and emergency maintenance activities related to BHS controls.
• Coordinate technical incidents with Senior Controls Support Engineer, Maintenance Manager, OEM specialists, and Global Service Desk as required.
• Monitor the health of PLC/control systems, communication status, alarms, recurring faults, and overall performance.
• Support contingency procedures, recovery trials, shutdown/start-up activities, and crisis recovery exercises.

Qualifications and Abilities

• Bachelor’s degree / Diploma in Electrical, Electronics, Instrumentation, Automation, Mechatronics, Control Engineering, or equivalent technical qualification.
• Minimum of 10 years of relevant experience in PLC/automation systems, with at least 5 years in Baggage Handling Systems.
• Strong practical knowledge of PLC programming, diagnostics, and troubleshooting; Siemens S7 / TIA Portal experience is preferred.
• In-depth understanding of Low-Level Controls (LLC), control panels, remote I/O systems, and industrial field devices.
• Familiarity with industrial communication networks such as PROFINET, PROFIBUS, Ethernet/IP, and Modbus TCP/IP.
• Experience with VFDs, motor control, encoders, sensors, scanners, photoelectric devices, and safety-related equipment.
• Proficiency in reading and understanding electrical drawings, control schematics, network diagrams, I/O lists, functional descriptions, and PLC logic.
• Knowledge of SCADA/HMI systems and their integration with PLC-controlled equipment.
• Basic understanding of server/client architecture, networking, virtualization, and IT infrastructure associated with BHS controls is preferred.
• Good English verbal and written communication skills and the ability to work independently within multidisciplinary teams.
• Understanding of safe working practices, permit-to-work requirements, and electrical/control-system safety protocols.

Responsibilities

• Diagnose faults in PLCs, control-systems, communications, and field devices and restore equipment within agreed response and resolution targets.
• Conduct Root Cause Analysis (RCA) for recurring or critical BHS control-system failures and recommend permanent corrective actions.
• Troubleshoot PLC hardware/software, I/O modules, communication interfaces, industrial networks, drives, sensors, actuators, and safety circuits.
• Monitor PLC alarms, diagnostic buffers, communication faults, system logs, and equipment status to identify potential failures.
• Perform PLC backup, program verification, comparison, restoration, and controlled software modifications as authorized.
• Ensure that PLC program changes and configuration modifications comply with approved change-management procedures.
• Support preventive maintenance and health checks of PLC panels, control cabinets, industrial network devices, remote I/O, and related equipment.
• Provide assistance during breakdown, corrective, and emergency maintenance during operational disruptions.
• Coordinate with Controls Support Engineer, IT Engineer, OEM, and Global Service Desk for incidents requiring higher-level support.
• Assist in testing and validating contingency modes, recovery procedures, failover scenarios, and operational recovery plans.
• Maintain current backups of PLC programs, configurations, parameters, network settings, and related documentation.
• Offer technical guidance and on-the-job support to maintenance technicians concerning PLC/control troubleshooting.
• Ensure compliance with site safety, cybersecurity, configuration-management, and maintenance procedures.
• Identify opportunities for improving system reliability, availability, maintainability, and operational performance.

List of Key Activities

• Execute daily PLC and control-system maintenance activities.
• Conduct daily/weekly inspections and health checks of PLC and LLC systems.
• Review PLC diagnostics, communication status, alarms, and system performance.
• Troubleshoot and resolve PLC-related equipment failures.
• Check communication between PLCs, SCADA/HMI, and field devices.
• Perform regular PLC program backups and configuration verification as per approved schedules.
• Assist in preventive and corrective maintenance of control panels and field devices.
• Support the replacement and configuration of PLC CPUs, communication modules, I/O modules, network switches, drives, and associated equipment.
• Participate in planned shutdowns, system restart activities, testing, commissioning, and operational trials.
• Aid in major incident coordination and provide timely technical updates to relevant stakeholders.
• Contribute to RCA and develop corrective/preventive action plans.
• Monitor repeated faults and pinpoint opportunities for permanent technical enhancements.
• Collaborate with Operations, IT, Maintenance, OEM specialists, and Global Service Desk.
• Maintain PLC-related maintenance records, fault reports, backup records, and change documentation.
• Work on weekly, monthly, and quarterly reports covering system failures, recurring faults, availability, and improvement activities.
• Support training and knowledge transfer to maintenance technicians and other site personnel.

Work Pattern

Differentiator

• Provide advanced troubleshooting capability for complex PLC and Low-Level Control faults affecting BHS availability.
• Understand the complete control chain from PLC logic through industrial networks to field devices and mechanical equipment.
• Identify root causes of repetitive faults rather than merely restoring equipment temporarily.
• Effectively coordinate between Controls, IT, Operations, Maintenance, OEM, and client teams.
• Develop and implement improvements in PLC programs, diagnostics, maintenance methods, tools, and system reliability.
• Maintain a strong focus on preventive actions, lifecycle management, and continuous improvement.