Senior Controls Engineer

Key Responsibilities

• System Design & Architecture
• Lead the conceptualization, design, and specification of complex control systems, including hardware selection (PLCs, HMIs, drives, sensors, actuators) and network architecture.
• Develop detailed electrical schematics, I/O lists, and wiring diagrams in collaboration with electrical engineers.
• Define control strategies, safety interlocks, and operational sequences, always considering manufacturing process flow, cycle time optimization, and overall equipment effectiveness (OEE).
• CoDeSys Programming & Development (Core Responsibility)
• Expertly program, test, and debug PLC logic using CoDeSys (IEC 61131-3) in various languages (ST, FBD, LD, SFC).
• Develop and implement reusable CoDeSys libraries, function blocks, and structured text routines, ensuring solutions are robust, maintainable, and scalable for production environments.
• Integrate and configure various fieldbus protocols (e.g., EtherCAT, PROFINET, Modbus TCP/IP, CANopen) within the CoDeSys environment.
• Develop and integrate HMI/SCADA applications using CoDeSys visualization or other compatible platforms, prioritizing operator usability, process visibility, and diagnostic capabilities for manufacturing personnel.
• Commissioning & Troubleshooting
• Lead the on-site commissioning, testing, and tuning of control systems, ensuring optimal performance and adherence to specifications, with a focus on achieving production targets and minimizing downtime.
• Perform advanced troubleshooting and diagnostics of complex hardware and software issues, often under pressure in a live manufacturing environment.
• Collaborate with mechanical, electrical, and software engineers to resolve system integration challenges, understanding their impact on the manufacturing line.
• Documentation & Standards
• Create and maintain comprehensive technical documentation, including functional specifications, design documents, test plans, and as-built drawings, which are essential for long-term manufacturing support and maintenance.
• Ensure all control system designs and implementations comply with relevant industry standards (e.g., UL, CE, NFPA, ISO, ANSI) and manufacturing specific regulations.
• Adhere to established coding standards and best practices for CoDeSys development.
• Project Leadership & Mentorship
• Lead technical aspects of projects, including scope definition, scheduling, and resource allocation, considering production timelines and resource availability within a manufacturing context.
• Provide technical guidance and mentorship to junior controls engineers, fostering their development in CoDeSys and control system design with an emphasis on practical manufacturing applications.
• Participate in design reviews and provide constructive feedback.
• Continuous Improvement & Manufacturing Optimization
• Stay abreast of new technologies, industry trends, and best practices in industrial automation and CoDeSys, specifically those applicable to improving manufacturing processes and efficiency.
• Proactively identify opportunities for process improvement, standardization, cost reduction, and other enhancements.

Qualifications

• Education: Bachelor's degree in Electrical Engineering, Mechatronics Engineering, Computer Engineering, or a closely related engineering discipline from an accredited university. Master's degree a plus.
• Experience: Minimum of 7+ years of progressive experience in industrial control systems design, programming, and commissioning, with a significant portion in manufacturing or production environments.
• Minimum of 3+ years of dedicated, hands-on experience programming and developing complex applications with CoDeSys (all versions/compatible platforms are valuable) for industrial machinery or production lines.
• Proven experience leading technical aspects of control system projects, from concept to production readiness.
• Technical Skills (Must-Haves): Expert-level proficiency in CoDeSys (IEC 61131-3) programming.
• Strong understanding of industrial networking protocols (e.g., EtherCAT, PROFINET, Modbus TCP/IP, CANopen, Ethernet/IP).
• Proficient with HMI/SCADA development and integration, with an emphasis on intuitive operator interfaces and robust data acquisition for manufacturing analytics.
• Solid understanding of electrical control panel design principles and safety standards (e.g., NFPA 79, UL 508A, EN ISO 13489, IEC 60204), and their application in a manufacturing plant.
• Experience with industrial safety systems (e.g., safety PLCs, light curtains, emergency stops) as applied to production equipment and personnel safety.
• Familiarity with CAD software for electrical design (e.g., AutoCAD Electrical, EPLAN).
• Ability to read and interpret complex electrical schematics and mechanical drawings.
• Demonstrated understanding of manufacturing processes, including but not limited to: material handling, assembly, machining, packaging, process control, and quality inspection.
• Knowledge of key manufacturing metrics such as OEE, cycle time, throughput, and their impact on control system design.
• Soft Skills: Excellent analytical and problem-solving abilities, particularly in diagnosing and resolving production issues.
• Strong written and verbal communication skills, able to convey complex technical information to production, maintenance, and management teams.
• Ability to work independently and as part of a multidisciplinary team, including collaboration with production operators and maintenance technicians.
• Demonstrated leadership potential and ability to mentor.
• Strong attention to detail and commitment to quality.
• Ability to manage multiple priorities and meet deadlines in a fast-paced manufacturing environment.