Programmable logic controllers, or PLCs, are rugged industrial computers that automate machinery, processes and building services. Major manufacturers include Siemens, Rockwell Automation (Allen‑Bradley), Schneider Electric, Mitsubishi Electric and Omron. Understanding these devices is the first step for anyone exploring what jobs involve programmable controllers.
PLCs matter because they deliver reliable, deterministic control and integrate with SCADA, HMIs and industrial networks such as Ethernet/IP, PROFINET and Modbus. That technical backbone drives demand across the UK in sectors from advanced manufacturing to food processing, water and wastewater, energy and facilities management.
This article adopts a product‑review style approach to careers in automation. It assesses roles as features, compares employers and sectors, and outlines tools and learning paths—vendor training like Siemens SCE and Rockwell Training, certificated apprenticeships from the Institute for Apprenticeships, and professional routes through the IET and IChemE.
Readers are graduates in engineering, technicians seeking upskilling, career changers and hiring managers who want clarity on PLC careers UK. Expect a clear view of programmable logic controller jobs, practical training options, likely salaries and progression so you can judge the value of investing in automation jobs UK.
What jobs involve programmable controllers?
Programmable logic controllers sit at the heart of modern industry. This section outlines common roles, sectors and day‑to‑day duties so you can match skills to opportunity.
Overview of roles that work directly with PLCs
The PLC jobs list includes Controls Engineer, PLC Programmer, Systems Integrator, Automation Engineer, Maintenance Technician, Automation Technician, Instrumentation Engineer, Process Control Engineer and Systems Commissioning Engineer.
Design roles such as Controls Engineer and Systems Integrator focus on control architecture, specification and system-level design. Implementation roles like PLC Programmer and Commissioning Engineer write ladder logic, structured text or function block code and carry out on-site tests. Hands-on support and maintenance come from Maintenance Technicians and Automation Technicians who troubleshoot faults and replace modules.
Contractor and consultancy opportunities offer project‑based PLC work for multiple clients. These posts often demand flexible travel and broad vendor experience with Siemens, Rockwell, Mitsubishi and others.
Industries with high demand for PLC expertise in the UK
Manufacturing, including automotive and aerospace subcontractors, has a high PLC density on production lines. Food and beverage firms rely on automation for hygiene and traceability on packaging and processing lines.
Utilities, water and wastewater sectors use PLCs for pumping stations and treatment plants. Energy and renewables need PLC skills for turbine control, battery storage and grid‑edge automation. Pharmaceuticals require validated control systems that tie into MES platforms.
Building services, facilities management and infrastructure projects, such as rail signalling and tunnel control, increasingly seek PLC expertise. Regional hotspots include the Midlands and North West for manufacturing, Scotland for renewables, and the South East for water and pharmaceuticals.
Typical responsibilities and daily tasks for PLC-related positions
Daily work often involves programming, testing and commissioning PLC ladder logic, structured text or function block diagrams using vendor IDEs such as TIA Portal, Studio 5000 and GX Works.
Engineers and programmers develop HMIs with AVEVA, Ignition or Rockwell PanelView and integrate SCADA platforms. Tasks include fault diagnosis, root cause analysis, firmware updates, backups and replacing faulty modules.
Producing electrical drawings, I/O lists and control narratives is routine. Staff liaise with electrical and mechanical engineers plus production managers to ensure smooth handovers at FAT and SAT.
Strict adherence to safety and compliance is essential. PLC responsibilities UK roles must cover functional safety (SIL), CE marking and ATEX where applicable, along with company lockout procedures.
Continuous improvement forms a regular focus. Typical activities include optimising sequences to boost productivity, implementing automation upgrades to cut downtime and using oscilloscopes, multimeters and diagnostic utilities for analysis.
- Tools: PLC racks, I/O modules, industrial networks, diagnostic utilities
- Software: version control, vendor IDEs, remote access tools
- Tests: FAT, SAT, commissioning handover and validation
Controls Engineer roles and career progression
Controls engineering opens routes into hands‑on automation, system design and project leadership. Employers look for practical ability and growth potential in controls engineer jobs across manufacturing, food production and regulated sectors such as pharmaceuticals.
Skills required for controls engineering
- Core technical skills: PLC programming with Siemens S7 and Allen‑Bradley Logix, electrical control design, motor and relay logic, plus basics of power distribution and safety circuits.
- Software and systems: SCADA and HMI configuration, PROFINET, EtherNet/IP and Modbus TCP, motion control, PID tuning and control loop design.
- CAD and documentation: reading and producing schematics in EPLAN or AutoCAD Electrical, wiring diagrams and bills of materials.
- Non‑technical strengths: project management, clear stakeholder communication, risk assessment and compliance with CE and machinery directives.
- Certifications that stand out: Chartered Engineer via the IET, vendor credentials such as Siemens SCE or Rockwell, and IOSH or NEBOSH for safety awareness.
Typical projects and employer expectations
Projects range from greenfield production lines and automated packaging to retrofits of legacy PLC fleets and line optimisation. Employers expect commissioning experience and the ability to lead FAT and SAT activities.
Controls teams must coordinate mechanical, electrical and software disciplines while meeting time and cost targets. Familiarity with functional safety, SIL assessments and validation routines is common in regulated industries.
Contractors and systems integrators commonly expect site travel around controls projects UK, flexible hours and adherence to client procedures during installations.
Pathways from graduate to senior controls engineer
- Entry routes: degrees in electrical, electronic or mechatronics engineering, or level 3–5 apprenticeships. Early titles include graduate controls engineer or junior automation engineer.
- Early career (0–3 years): build PLC skills, support commissioning and gain field experience with vendor tools.
- Mid career (3–8 years): lead small projects, create design packages, choose vendors and mentor juniors while sharpening controls engineering skills.
- Senior roles (8+ years): take on systems architecture, client liaison and commercial responsibility. Options include engineering management or specialist consultancy.
Continued professional development through vendor training, MSc modules or short automation courses helps move a career path controls engineer forward. Practical exposure to real controls projects UK and demonstrable project outcomes remain decisive for promotion.
Maintenance Technician and Automation Technician opportunities
Careers for maintenance and automation technicians offer clear routes into high-demand roles across the UK. These positions balance hands-on repair with evolving control-system work. Readers will find practical paths that lead from entry-level roles to specialist technician jobs UK.
Difference between maintenance and automation technician roles
Maintenance technicians focus on plant reliability. They carry out mechanical and electrical fault finding, routine servicing and reactive repairs. Work often includes simple PLC diagnostics and component replacement, not major code rewrites.
Automation technicians take a software-first approach. Tasks include programming basic PLC logic, updating HMI screens and supporting system upgrades. They bridge controls engineers and maintenance teams while improving production efficiency.
Overlap exists. Both need electrical safety competence, the ability to read wiring diagrams and strong troubleshooting skills. Employers value candidates who can switch between physical repairs and PLC fault diagnosis.
Common industries: manufacturing, food and beverage, utilities
Manufacturing roles cover assembly lines, conveyors and press lines. Maintenance technicians minimise downtime. Automation technicians focus on cycle-time improvements and process optimisation.
In food and beverage, technicians must follow strict hygiene regimes and traceability rules while preserving control integrity. Tasks demand careful cleaning practices alongside electrical work.
Utilities and water sectors involve remote PLC and RTU management, telemetry and pump control. Scheduled inspections and emergency call-outs are common. Skills in telemetry raise a candidate’s value for technician jobs UK.
Other sectors with steady demand include pharmaceuticals, petrochemical, packaging and building services. These areas reward experience with robust documentation and safety awareness.
Essential qualifications, certifications and on-the-job training
Core qualifications often include an NVQ or BTEC in electrical or electronic engineering, City & Guilds or apprenticeship completion. Higher roles may ask for HNC, HND or a foundation degree. Clear PLC technician qualifications support progression.
Electrical safety certifications matter. Knowledge of the 18th, 19th or 20th Edition wiring regulations, basic PAT testing and site cards such as CSCS or CCNSG improve employability. Health and safety courses like IOSH Working Safely and lockout/tagout are standard.
Vendor training from Siemens, Rockwell or Schneider provides targeted PLC programming and HMI skills. On-the-job mentoring, shadowing during commissioning and incremental vendor certification help develop an effective maintenance technician PLC profile.
Employers value demonstrable experience and a willingness to learn. Combining formal PLC technician qualifications with practical site exposure creates a strong foundation for long-term careers in technician jobs UK.
For a daily view of technician tasks and field routines, consult this practical overview on HVAC duties what an HVAC technician does.
Systems Integrator and PLC Programmer positions
The role brings together engineering, software and fieldwork to make machines and sites run reliably. Employers seek people who can translate process needs into robust control systems and who can travel for commissioning and support. Systems integrator jobs in the UK often focus on end‑to‑end delivery, from design to handover, with emphasis on health and safety and supplier relationships with Siemens, Rockwell and Schneider.
What a PLC programmer does day-to-day
A PLC programmer daily tasks include writing, testing and debugging code in ladder logic, structured text and function blocks. They convert control specifications into I/O lists and program structure, then perform simulation and stepwise testing to validate sequences and interlocks.
Programmers work with mechanical and electrical engineers to resolve interface issues and ensure sensors and actuators map correctly. They maintain documentation such as source code comments, version history and commissioning checklists.
During commissioning they provide technical support, respond to field issues and implement software updates or patches. Strong communication helps close loops between design, production and maintenance teams.
Systems integration: combining PLCs with SCADA and HMIs
Systems integrators design architectures that link PLCs to operator interfaces and supervisory control for visualisation, data logging and alarm management. PLC and SCADA integration uses OPC UA, MQTT or vendor drivers to ensure reliable tag exchange.
Integration tasks include tag mapping, alarm strategy, historian configuration and network segmentation to support cybersecurity standards such as IEC 62443. Remote access is configured securely via VPNs and industrial firewalls for ongoing support.
Examples of projects and tools used by integrators
Common projects include automated palletising cells, end‑of‑line robotics with vision, water treatment PLC upgrades and packaging machine retrofits that add recipe control and traceability. Each project follows a lifecycle of requirements gathering, control design, software development, FAT, site installation, SAT and post‑commissioning support.
- Control engineering tools: Siemens TIA Portal, Rockwell Studio 5000, Schneider EcoStruxure and Mitsubishi GX Works.
- SCADA/HMI platforms: Ignition, AVEVA (formerly Wonderware), Siemens WinCC and Rockwell FactoryTalk for PLC and SCADA integration.
- Hardware platforms: Siemens S7‑1500, Allen‑Bradley ControlLogix and Schneider Modicon for robust machine control.
- Consultancy models: systems integrator jobs can be fixed‑price or time‑and‑materials, with reputation for safety and vendor partnerships affecting tender success.
Practical familiarity with integration tools UK organisations use gives candidates an edge. Mastery of software, hardware and secure networking helps deliver projects that meet performance, safety and compliance goals.
Instrumentation Engineer and Process Control careers
Instrumentation and process control blend hands‑on hardware with analytical thinking. Instrumentation engineers specify, install and maintain the sensors that feed process variables into PLCs and DCS, ensuring accurate readings for pressure, flow, level, temperature and pH. This work underpins safe, efficient production across pharmaceuticals, food and utilities.
Role of instrumentation in PLC-controlled processes
Field devices from Endress+Hauser, Yokogawa, Honeywell, ABB and Siemens convert physical signals into data used by PLCs. Instrumentation engineers set calibration regimes and traceability so control logic reacts to real process values. They define alarm thresholds and hand over validated signals to process control teams for logic design.
Regular loop checking and documentation keeps plants compliant. In regulated sectors, accuracy and audit trails matter as much as uptime.
Key technical knowledge: sensors, PID loops and control strategies
Practical knowledge of RTDs, thermocouples, ultrasonic and radar level sensors is essential. Signal conditioning standards such as 4–20 mA, HART and fieldbus must be second nature to troubleshoot and integrate devices into control systems.
Understanding PID fundamentals and PID tuning methods like Ziegler–Nichols or Cohen–Coon helps engineers set stable loops. Skills in cascade, feedforward and anti‑windup techniques improve response where plant dynamics are complex.
Advanced strategies such as multivariable control, inferential measurements and alarm management (ISA 18.2) raise process performance. Familiarity with calibrators from Fluke or Beamex supports rigorous loop testing and regulatory compliance.
Career pathways and cross-disciplinary opportunities
- Entry routes include degrees in instrumentation, process control, chemical or electrical engineering and specialist apprenticeships.
- Typical progression moves from instrumentation technician to instrumentation engineer, then to process control engineer and control systems architect.
- Cross-disciplinary roles link to data analytics teams working with OPC/PI historians, reliability engineering and project management.
Demand for instrumentation engineer jobs grows as Industry 4.0 expands. Those who combine device expertise with skills in PID tuning and data integration will find strong prospects within sensors and instrumentation UK markets and broader process control careers.
Emerging jobs in industrial automation and robotics
The shift to Industry 4.0 is creating new roles across manufacturing, utilities and logistics. Robotics engineers and robot programmers from vendors such as ABB, Fanuc, KUKA and Universal Robots now work on programming robot cells, integrating vision systems and linking robots to PLCs. These emerging automation jobs often require hands‑on experience with industrial robots and a practical grasp of safety and human‑robot collaboration.
Complementary positions include IIoT engineers and automation data analysts who connect PLCs and field devices to cloud platforms like Microsoft Azure IoT and AWS IoT Greengrass. Data engineers use historian systems such as PI System and Ignition plus Python toolchains to enable predictive maintenance and OEE improvements. These Industry 4.0 jobs blend control knowledge with networking, data handling and analytics.
Operational technology security is another growth area: OT cybersecurity specialists secure PLC networks, implement IEC 62443 compliance and work with vendors such as Palo Alto Networks, Fortinet and Nozomi Networks. Cobot integrators and vision specialists tailor human‑robot cells using Cognex or Keyence cameras. In all cases, PLC and robotics roles remain foundational; understanding I/O, real‑time constraints and control logic gives professionals a strong platform to move into these newer disciplines.
To make the transition, combine PLC competence with scripting, IIoT protocols and vendor robotics courses like Universal Robots Academy. Seek employer training, vendor certifications and demonstrable project experience through automation upgrades or pilot projects. Join bodies such as the IET and attend shows like Advanced Engineering UK to network and explore robotics careers UK. For a concise view of how automation careers stay future‑proof, see this brief guide at automation career outlook.
