Sr. Controls Engineer

About the role

The Senior Controls, Automation & Robotics Engineer role leads the automation strategy, controls team, and continuous improvement initiatives at a fast-paced, high-volume manufacturing site. You will serve as the technical authority for PLC programming, robotics, motion control, automation reliability, and capital projects while managing a team of Controls Technicians and automation resources.

Responsibilities

• Lead, mentor, and develop a team of 5–6 Controls Technicians and automation resources, providing day-to-day direction, coaching, and performance feedback.
• Serve as the site’s technical expert for PLCs, robotics, motion controls, drives, and automation systems, acting as the primary point of contact for complex controls issues.
• Perform and support PLC programming, including new code development, troubleshooting, and modifications to improve performance, reliability, and safety.
• Lead automation-related capital projects from concept through commissioning, including requirements definition, design reviews, FATs, SATs, startup, and ramp-up activities.
• Drive automation reliability improvements by conducting root cause analysis on downtime events and implementing effective corrective and preventive actions.
• Manage automation obsolescence and modernization projects, including controls upgrades, platform migrations, and infrastructure improvements.
• Improve OEE, uptime, and overall production performance through targeted controls and automation enhancements.
• Partner closely with Operations, Maintenance, Engineering, and Quality teams to identify issues, prioritize projects, and improve manufacturing performance.
• Provide technical coaching, training, and development for controls personnel to build internal expertise in PLCs, robotics, motion control, and automation systems.
• Manage external controls contractors, system integrators, and OEM resources, ensuring high-quality deliverables and adherence to site standards.
• Support continuous improvement initiatives by identifying opportunities for automation, standardization, and optimization of manufacturing and packaging systems.
• Contribute to the site’s long-term automation strategy, aligning projects and upgrades with business objectives and future digitalization efforts.

Requirements

• Bachelor’s degree in Electrical Engineering, Controls Engineering, Mechatronics, Robotics Engineering, or a related engineering discipline.
• 10+ years of controls, automation, and robotics engineering experience within a manufacturing environment.
• Proven experience leading and developing technical teams, including direct management of Controls Technicians, Automation Engineers, or similar resources.
• Strong hands-on PLC programming experience, including troubleshooting, modifications, and new program development.
• Experience working with high-speed manufacturing equipment and production environments.
• Experience with robotics, motion control systems, variable frequency drives (VFDs), HMIs, instrumentation, and industrial automation systems.
• Experience leading controls and automation-related capital projects from concept through commissioning and startup.
• Experience participating in design reviews, FATs, SATs, commissioning, startup, and equipment ramp-up activities.
• Demonstrated success improving manufacturing performance through automation, controls optimization, and continuous improvement initiatives.
• Experience identifying and resolving automation-related downtime through root cause analysis and corrective actions.
• Experience supporting controls modernization, equipment upgrades, and obsolescence management projects.
• Ability to lead technical troubleshooting efforts and provide coaching and development to controls personnel.
• Strong understanding of industrial control systems, electrical systems, and manufacturing automation infrastructure.
• Excellent communication skills with the ability to explain technical concepts clearly and lead cross-functional teams.
• Self-driven leadership style with the ability to take ownership of automation strategy and execution with minimal supervision.

Qualifications

• Experience with Allen-Bradley / Rockwell Automation platforms, including ControlLogix, Studio 5000, and FactoryTalk.
• Schneider Electric automation experience.
• Background in Food & Beverage, Consumer Products, Chemical, or Pharmaceutical manufacturing environments.
• Experience leading projects, technicians, contractors, or small technical teams, even without formal leadership titles.
• Experience mentoring or training junior controls personnel.
• Demonstrated ability to take ownership of automation initiatives and drive results across functions.
• Strong influencing skills with the ability to lead and motivate others without direct authority.
• Desire to grow into a broader leadership role while remaining closely engaged with technology and hands-on engineering work.