Senior Controls Engineer
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About the role
The Senior Controls Engineer will design, program, install, and maintain industrial automation and control systems, including PLCs, SCADA platforms, robotics, and related technologies. This role supports the integration of AI-driven solutions into manufacturing operations, enabling predictive maintenance, real-time decision making, adaptive automation, and continuous process optimization. The ideal candidate combines strong technical expertise with a systems-thinking mindset and a passion for driving operational excellence.
Responsibilities
- Design, develop, program, and maintain PLC, HMI, SCADA, DCS, robotics, and industrial networking systems.
- Integrate AI and machine learning outputs into automation platforms to support predictive maintenance, anomaly detection, and adaptive process control.
- Troubleshoot and optimize existing manufacturing automation systems to improve reliability, efficiency, and performance.
- Support implementation of Industry 4.0 initiatives, including data collection, analytics, edge computing, and smart manufacturing technologies.
- Lead automation improvement projects focused on productivity, quality, safety, and process consistency.
- Collaborate with operations, maintenance, engineering, and leadership teams to identify and implement system enhancements.
- Develop and maintain control system documentation, standards, and best practices.
- Evaluate new technologies and recommend scalable automation solutions.
- Analyze operational data to identify trends, resolve issues, and drive continuous improvement initiatives.
- Serve as a technical resource for controls, automation, and AI-enabled manufacturing systems.
Skills
- Strong analytical and problem-solving skills with the ability to interpret and leverage data for decision-making.
- Systems-thinking approach with the ability to understand impacts across multiple processes and functions.
- Hands-on experience designing, programming, commissioning, and supporting industrial automation systems.
- Continuous improvement mindset focused on optimization, standardization, and operational efficiency.
- Ability to anticipate technical challenges and proactively implement solutions.
- Experience establishing and supporting best practices for controls architecture and automation design.
- Strong communication and collaboration skills with the ability to influence stakeholders across all levels of the organization.
- Ability to prioritize effectively in fast-paced manufacturing environments and respond to critical issues when needed.
- Proven track record of building relationships with production, maintenance, and engineering teams.
Qualifications
- Bachelor’s degree in Electrical Engineering, Controls Engineering, Automation Engineering, or a related field.
- Minimum of 3 years of controls or automation engineering experience within a manufacturing environment.
- Experience programming and troubleshooting PLC-based control systems.
- Authorization to work in the United States without current or future sponsorship requirements.
- Experience with Allen-Bradley and/or Siemens PLC platforms.
- Strong HMI, SCADA, industrial networking, and communication protocol experience.
- Experience with robotics integration and automated manufacturing systems.
- Exposure to Python, machine learning applications, AI-enabled automation, or edge computing technologies.
- 3+ years of hands-on automation engineering experience supporting manufacturing operations.
- Knowledge of Industry 4.0 technologies, data collection platforms, and predictive maintenance strategies.
Work Environment
The work environment involves fast-paced manufacturing settings where the ability to respond to critical issues is essential. The role requires collaboration with various teams, including operations, maintenance, and engineering, to drive system enhancements and process optimizations.
Pay
The pay range for this position is $90,000 - $120,000/yr. Individual compensation offered within this range will depend on qualifications, skills, relevant experience, job knowledge, geographic location, internal equity, and other pertinent job-related factors.
Benefits
- Medical, dental, and vision insurance
- 401(k) retirement plan
- Life and disability insurance
- Employee Assistance Program (EAP)
- PTO and paid holidays
- Tuition assistance and training opportunities
- Parental/adoption benefits (availability can vary by position/location)
Schedule
This is a permanent, fully onsite position based in Whitehall, MI.