Sr. Controls Engineer

Position Overview

We are seeking a Senior Controls Engineer to design, develop, and commission industrial control systems that support automation projects across manufacturing and process environments. The ideal candidate will lead controls engineering efforts architecting PLC/HMI/SCADA solutions, integrating hardware and software, ensuring reliable operation, and mentoring junior engineers while collaborating with project managers, electrical engineers, and operations teams to meet schedule, budget, safety, and quality targets.

Key Responsibilities

• Lead design, programming, testing, and commissioning of PLC, HMI, and SCADA systems for new and retrofit projects.
• Develop control system architectures, I/O lists, network topologies, and panel wiring diagrams in coordination with electrical and mechanical teams.
• Program and troubleshoot PLCs (Rockwell, Siemens), create HMI screens, and configure SCADA platforms (Ignition, Wonderware/AVEVA).
• Implement industrial networking and communications (Ethernet/IP, Profinet, OPC UA, Modbus) and ensure robust cyber-security practices for control systems.
• Prepare control system documentation including functional specifications, control narratives, ladder/structured text code, loop diagrams, test plans, and as-built drawings.
• Lead Factory Acceptance Testing (FAT), Site Acceptance Testing (SAT), and oversee on-site commissioning and start-up activities.
• Perform root-cause analysis and provide timely troubleshooting and support for production downtime and intermittent faults.
• Coordinate with suppliers, integrators, and cross-functional teams to ensure component compatibility and successful system integration.
• Mentor and train junior engineers and technicians, review code and design deliverables, and enforce engineering standards and best practices.
• Contribute to project planning, cost estimating, schedules, and continuous improvement initiatives related to controls and automation.

Qualifications

• Bachelor's degree in Electrical Engineering, Control Systems, Mechatronics, or a related field; equivalent experience considered.
• 10+ years of progressive experience in controls engineering within industrial manufacturing or process industries.
• Proven proficiency programming and commissioning Rockwell (RSLogix/Studio 5000) and Siemens (TIA Portal) PLCs.
• Strong experience developing HMIs and SCADA systems, including Ignition and Wonderware/AVEVA platforms.
• Solid understanding of industrial networking (Ethernet/IP, Profinet, OPC UA, Modbus) and control system cybersecurity fundamentals.
• Experience with VFDs, motor control, instrumentation, PID tuning, and basic motion control concepts.
• Demonstrated ability to create clear technical documentation: functional specs, control narratives, I/O lists, and test plans.
• Hands-on experience with FAT/SAT procedures, commissioning, and field troubleshooting; willing to travel to project sites as required.
• Excellent problem-solving, communication, leadership, and project coordination skills; experience mentoring junior staff.
• Preferred certifications: Rockwell Certified, Siemens Certified, Certified Automation Professional (CAP), or related credentials.

Benefits

• Paid holidays
• PTO
• Health/dental/vision
• Short/long-term disability
• Life insurance
• 401(k) program with an employee match
• Parental leave policy
• Relocation assistance may be available