Senior Controls Engineer

About the role

Daniels Health is seeking an experienced Senior Controls Engineer to join our growing US engineering team and help design, build, and optimize the next generation of automated medical waste processing systems. This is a hands‑on, high‑impact role where you will work at the intersection of PLC control systems, robotics, and machine vision in safety‑critical, high‑throughput industrial environments.

Responsibilities

• Design, develop, program, and maintain PLC‑based control systems for advanced medical waste processing equipment
• Integrate, program, and commission industrial robots for material handling, sorting, and automated processing
• Design, implement, and optimize machine vision systems for detection, classification, inspection, and process verification
• Train, tune, and validate vision models to ensure accuracy, robustness, and regulatory compliance
• Collaborate with mechanical, electrical, robotics, and software engineering teams to deliver fully integrated automation solutions
• Support commissioning, troubleshooting, and root‑cause analysis across controls, robotics, and vision systems
• Prepare and review electrical, hydraulic, and pneumatic control drawings for new equipment and system upgrades
• Develop system documentation including functional specifications, control narratives, operator manuals, maintenance documentation, and validation protocols
• Ensure all control system designs comply with applicable US medical waste, environmental, and machine safety regulations
• Work closely with suppliers, system integrators, and external service providers to deliver projects on time and to specification
• Drive continuous improvement in automation performance, reliability, safety, and sustainability

Requirements

• Bachelor’s degree in Electrical Engineering, Mechatronics, Automation Engineering, or a related discipline
• 8+ years of experience in a controls or automation engineering role
• Strong PLC and HMI programming experience with platforms such as Allen‑Bradley, Siemens, Beckhoff, or Automation Direct
• Hands‑on industrial robotics experience including programming, commissioning, and safety integration (FANUC, ABB, KUKA, Hyundai, or similar)
• Strong machine vision experience using Cognex, Keyence, OpenCV, or comparable systems
• Solid understanding of industrial communication protocols including EtherNet/IP, Modbus, and OPC UA
• Experience with motion control, servo systems, and safety‑rated automation components
• Ability to read and create electrical schematics, P&IDs, and mechanical drawings
• Experience working in regulated or safety‑critical environments such as medical, pharmaceutical, or waste processing is highly desirable
• Strong troubleshooting, analytical, and problem‑solving skills
• Excellent written and verbal communication skills and the ability to collaborate across cross‑functional teams
• Ability to work independently and manage projects with multiple stakeholders and vendors
• Willingness to travel domestically and internationally as required

Qualifications

• Strong PLC and HMI programming experience with platforms such as Allen‑Bradley, Siemens, Beckhoff, or Automation Direct
• Hands‑on industrial robotics experience including programming, commissioning, and safety integration (FANUC, ABB, KUKA, Hyundai, or similar)
• Strong machine vision experience using Cognex, Keyence, OpenCV, or comparable systems
• Solid understanding of industrial communication protocols including EtherNet/IP, Modbus, and OPC UA
• Experience with motion control, servo systems, and safety‑rated automation components
• Ability to read and create electrical schematics, P&IDs, and mechanical drawings
• Experience working in regulated or safety‑critical environments such as medical, pharmaceutical, or waste processing is highly desirable
• Strong troubleshooting, analytical, and problem‑solving skills
• Excellent written and verbal communication skills and the ability to collaborate across cross‑functional teams
• Ability to work independently and manage projects with multiple stakeholders and vendors
• Willingness to travel domestically and internationally as required

Skills

• Strong PLC and HMI programming experience with platforms such as Allen‑Bradley, Siemens, Beckhoff, or Automation Direct
• Hands‑on industrial robotics experience including programming, commissioning, and safety integration (FANUC, ABB, KUKA, Hyundai, or similar)
• Strong machine vision experience using Cognex, Keyence, OpenCV, or comparable systems
• Solid understanding of industrial communication protocols including EtherNet/IP, Modbus, and OPC UA
• Experience with motion control, servo systems, and safety‑rated automation components
• Ability to read and create electrical schematics, P&IDs, and mechanical drawings
• Experience working in regulated or safety‑critical environments such as medical, pharmaceutical, or waste processing is highly desirable
• Strong troubleshooting, analytical, and problem‑solving skills
• Excellent written and verbal communication skills and the ability to collaborate across cross‑functional teams
• Ability to work independently and manage projects with multiple stakeholders and vendors
• Willingness to travel domestically and internationally as required

Benefits

We offer a comprehensive benefit package that includes:

• Medical, dental, and vision insurance
• Retail savings plans with company match contributions
• Paid vacation and sick time
• Wellness resources
• Life insurance
• Professional development opportunities

Pay

The pay range for this position is $125,375to $141,079 salary. Actual compensation within this range will depend on factors unique to each candidate, such as prior experience, skill, certifications, and work location. Pay variations by location reflect local conditions and differences in the cost of labor.

Schedule

This is a hybrid role. Travel will be required throughout the USA and Canada and some other overseas locations. Travel to Taylor, Michigan will be required for Induction training.