Controls Support Engineer

Role Overview

Controls Support Engineer at Vanderlande. A mid to high level technical expert role for PLC and Low-Level Control (LLC) infrastructure of Baggage Handling Systems, responsible for ensuring reliable operation, maintenance, troubleshooting and optimization of PLC-controlled equipment and associated control systems.

Role Purpose

Provide first-line and advanced technical support for baggage handling system controls, diagnose and resolve PLC and low-level control incidents, support the Maintenance Manager in maintaining system availability and reliability, and act as the technical focal point for control-related faults, modifications, testing and performance issues while supporting continuous improvement of site-based BHS control and maintenance services.

Key Responsibilities

Troubleshooting and Fault Resolution

• Diagnose PLC, control-system, communication and field-device faults and restore equipment within agreed response and resolution targets.
• Troubleshoot PLC hardware and software, I/O modules, communication interfaces, industrial networks, drives, sensors, actuators and safety circuits.
• Perform Root Cause Analysis (RCA) for recurring or critical BHS control-system failures and recommend permanent corrective actions.
• Attend and resolve PLC-related breakdown calls.
• Support contingency procedures, recovery trials, shutdown and start-up activities and crisis recovery exercises.

Monitoring and Diagnostics

• Monitor PLC alarms, diagnostic buffers, communication faults, system logs and equipment status to identify potential failures.
• Monitor PLC and control-system health, communication status, alarms, recurring faults and overall performance.
• Check PLC-to-PLC, PLC-to-SCADA/HMI and PLC-to-field-device communication.
• Review PLC diagnostics, communication status, alarms and system performance.
• Monitor repeated faults and identify opportunities for permanent technical improvements.

Maintenance and System Support

• Support preventive, corrective, breakdown and emergency maintenance activities related to BHS controls.
• Support preventive maintenance and health checks of PLC panels, control cabinets, industrial network devices, remote I/O and related equipment.
• Perform daily and weekly inspections and health checks of PLC and LLC systems.
• Support breakdown, corrective and emergency maintenance during operational disruptions.
• Support replacement and configuration of PLC CPUs, communication modules, I/O modules, network switches, drives and associated equipment.

Configuration and Change Management

• Perform PLC backup, program verification, comparison, restoration and controlled software modifications as authorized.
• Ensure PLC program changes and configuration modifications follow approved change-management procedures.
• Perform PLC program backups and configuration verification as per approved schedules.
• Maintain updated backups of PLC programs, configurations, parameters, network settings and related technical documentation.
• Maintain PLC-related maintenance records, fault reports, backup records and change documentation.

Coordination and Communication

• Coordinate technical incidents with Senior Controls Support Engineer, Maintenance Manager, OEM specialists and Global Service Desk when required.
• Coordinate with Operations, IT, Maintenance, OEM specialists and Global Service Desk.
• Support major incident coordination and provide timely technical updates to relevant stakeholders.
• Provide technical guidance and on-the-job support to maintenance technicians regarding PLC and control troubleshooting.
• Support training and knowledge transfer to maintenance technicians and other site personnel.

Testing, Commissioning and Improvement

• Support testing and validation of contingency modes, recovery procedures, failover scenarios and operational recovery plans.
• Participate in planned shutdowns, system restart activities, testing, commissioning and operational trials.
• Participate in RCA and preparation of corrective and preventive action plans.
• Identify opportunities to improve system reliability, availability, maintainability and operational performance.
• Contribute to weekly, monthly and quarterly reports covering system failures, recurring faults, availability and improvement activities.

Compliance and Safety

• Ensure compliance with site safety, cybersecurity, configuration-management and maintenance procedures.
• Good understanding of safe working practices, permit-to-work requirements and electrical and control-system safety procedures.

Qualifications & Experience

• Bachelor's degree or Diploma in Electrical, Electronics, Instrumentation, Automation, Mechatronics, Control Engineering or equivalent technical qualification.
• Minimum 10 years of relevant experience in PLC and automation systems.
• Preferably 5 years of experience in Baggage Handling Systems.

Skills & Competencies

• Strong practical knowledge of PLC programming, diagnostics and troubleshooting.
• Siemens S7 and TIA Portal experience is preferred.
• Strong knowledge of Low-Level Controls (LLC), control panels, remote I/O systems, industrial field devices and control architecture.
• Good knowledge of 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.
• Ability to read and understand electrical drawings, control schematics, network diagrams, I/O lists, functional descriptions and PLC logic.
• Knowledge of SCADA and HMI systems and their interface with PLC-controlled equipment.
• Basic understanding of server and client architecture, networking, virtualization and IT infrastructure associated with BHS controls is preferred.
• Good English verbal and written communication skills.
• Ability to work independently within multidisciplinary teams.
• Advanced troubleshooting capability for complex PLC and Low-Level Control faults affecting BHS availability.
• Ability to understand the complete control chain from PLC logic through industrial networks to field devices and mechanical equipment.
• Ability to identify root causes of repetitive faults rather than only restoring equipment temporarily.
• Effective coordination between Controls, IT, Operations, Maintenance, OEM and client teams.
• Development and implementation of improvements in PLC programs, diagnostics, maintenance methods, tools and system reliability.
• Strong focus on preventive actions, lifecycle management and continuous improvement.