Senior Controls Engineer
Senior Controls Engineer
The Senior Controls Engineer is responsible for leading the design, development, and integration of advanced automation and control systems. This position provides technical leadership across multiple projects, mentors less experienced engineers, and ensures that all solutions meet stringent safety, performance, and reliability standards. The role requires collaboration across departments and direct engagement with clients to deliver successful outcomes.
Key Responsibilities
- Drive the design and implementation of complex control systems, including PLCs, HMIs, motion control, and safety systems.
- Diagnose and resolve challenging system issues, conduct root cause analysis, and implement corrective measures.
- Define system architecture and ensure adherence to industry standards and best practices.
- Identify process inefficiencies in control system development and introduce improvements to enhance productivity and quality.
- Provide technical guidance, mentorship, and review for junior and mid-level engineers.
- Collaborate with internal teams to establish project scope, budgets, and timelines.
- Maintain professional communication with clients to ensure positive representation and project success.
- Manage multiple projects concurrently, ensuring alignment with organizational objectives and deadlines.
- Work closely with multidisciplinary teams to achieve seamless integration of control systems into overall solutions.
- Demonstrate reliability in attendance, meeting participation, and timely completion of deliverables.
- Exhibit strong communication and teamwork skills.
Qualifications
Education:
Bachelor's degree in engineering or a related discipline; specialization in controls engineering preferred.
Experience:
Minimum of 5 years of relevant engineering experience, ideally within a manufacturing or industrial automation environment.
Technical Skills:
- Proficiency in Microsoft Office applications.
- Advanced PLC programming (Ladder Logic, Structured Text); experience with WAGO and CoDeSys is advantageous.
- Skilled in HMI/SCADA development and integration with PLCs.
- Knowledge of motion control systems, servo drives, and VFDs.
- Strong understanding of industrial safety devices and safety PLCs (e.g., E-stops, light curtains, safety relays, interlocks).
- Familiarity with communication protocols such as EtherNet/IP, Modbus TCP, Profinet, MQTT, and OPC UA.
- Experience with machine vision systems and barcode reader integration.
- Exposure to industrial robotics and collaborative robots (e.g., UR, Fanuc, ABB, KUKA).
- Ability to interpret electrical schematics and develop I/O lists.
- Excellent written and verbal communication skills.
- Strong organizational abilities and attention to detail.
- Demonstrated leadership, strategic planning, and team development skills.
- Knowledge of UL508A, NFPA 79, NEC, and IEC standards.
Preferred:
- Extensive experience in control system design and project leadership, including reusable code libraries and templates.
- Background in large-scale automation projects (e.g., material handling, conveyor systems).
- Comprehensive understanding of electrical safety practices for various voltages and currents.
Additional Requirements
- Ability to walk, stand, and crouch for equipment inspection and troubleshooting.
- Comfortable using basic hand tools and diagnostic instruments.
- Willingness to travel up to 10%.
FAQs
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