Senior Controls Engineer - PLC, Conrols Engineer, HMI

This role is central to designing, programming, and optimizing automated production systems in a high-volume manufacturing environment. The Senior Controls Engineer drives improvements in equipment performance, throughput, and uptime while supporting the commissioning of complex, custom-built machinery.

Responsibilities

• Develops PLC programs in ladder logic and structured text for production equipment, automated transfer systems, robotics, and quality inspection devices.
• Modifies and optimizes existing PLC, motion control, and servo logic to improve cycle time, uptime, and overall equipment performance.
• Integrates sensors, thermal devices, machine vision systems, actuators, and safety components, including configuration of I/O and industrial communication protocols such as Ethernet/IP, Modbus, and Profinet.
• Leads debugging, diagnostics, and root-cause analysis for PLCs, HMIs, robotics, motion systems, and safety systems during installation, startup, and commissioning.
• Supports equipment start-up, factory and site acceptance testing, final commissioning, and integration into manufacturing workflows.
• Analyzes automated processes to identify bottlenecks, inefficiencies, and opportunities for throughput, quality, and reliability improvements.
• Creates and maintains electrical schematics, functional design specifications, PLC and HMI documentation, standards, and change records.
• Provides technical oversight to internal teams and suppliers while training maintenance and production personnel on new systems and upgrades.

Requirements

• Bachelor’s degree in electrical engineering, controls engineering, automation, mechatronics, software engineering, or a related discipline.
• Extensive hands-on PLC programming experience using ladder logic and structured text.
• Experience designing and implementing new production processes and automation systems.
• Demonstrated ability to develop PLC programs from the ground up for new manufacturing equipment.
• Experience integrating sensors, motion systems, machine vision, and automation hardware.
• Strong troubleshooting skills across electrical, PLC, robotic, and automation systems.
• Experience with Allen-Bradley/Rockwell Automation and/or Siemens PLC platforms.
• Ability to read and interpret electrical schematics using EPLAN or AutoCAD.
• Working knowledge of SCADA, MES, data acquisition systems, and industrial networking.
• Experience commissioning custom-built equipment or greenfield production lines is preferred.
• Experience with robotics platforms such as Fanuc, Kuka, ABB, or Kawasaki is strongly preferred.
• Must be currently authorized to work in the United States without the need for sponsorship for a non-immigrant visa.

Benefits

• Competitive salary range of $120,000 - $135,000 plus bonus eligibility
• Medical, Dental, and Vision insurance
• 401(k) program
• Generous Paid Time Off plan
• Paid maternity and paternity leave
• Commuter benefits
• Additional supplemental benefits