Sr. Controls Engineer

Responsibilities

• Lead hands-on programming, debugging, and commissioning of Siemens and Allen Bradley/Rockwell PLCs and HMIs for new and existing automation equipment.
• Develop, modify, and maintain PLC code structures, HMI screens, safety circuits, device mapping, and networking configurations to ensure robust and standardized automation performance across all equipment.
• Execute the scaling-equipment design-review campaign, converting findings into hardened, detailed technical deliverables for OEM vendors.
• Review vendor electrical schematics, controls architectures, and PLC/HMI logic.
• Own the FAT/SAT campaign: author standardized acceptance protocols, covering PLC logic conformance, HMI/alarm acceptance, interlock validation, and network/security verification.
• Run the program-wide punch list and coordinate witness assignments.
• Integrate with Quality’s validation system - protocols live in Quality’s framework and carry Quality’s approval; you author the automation content and align with Manufacturing Engineering’s master schedule and process acceptance criteria.
• Drive the integration and commissioning of robotics, vision systems, AGVs, conveyors, and motion control systems—including servos and VFDs—to enable seamless material flow and high reliability production operations.
• Configure and maintain communications between PLCs/HMIs and higher level systems (MES/SCADA).
• Develop and troubleshoot SCADA tags, transactions, alarming, and data acquisition as required.
• Serve as a senior-level escalation point for diagnosing complex automation issues involving networks, motion systems, instrumentation, and industrial communication protocols.

Qualifications

• Bachelor’s or Master's degree in electrical engineering, Automation Engineering, Mechatronics, or related field with 7+ years of direct industrial automation and controls engineering experience.
• Strong hands-on experience programming and commissioning Siemens and Allen Bradley/Rockwell PLCs and HMIs.
• Demonstrated multi-vendor acceptance campaign management, disciplined change control with the ability to triage punch items to fix in situ or kick back to a vendor.
• Technical writing that vendors and auditors can both execute against.
• Deep understanding of servos, VFDs, highspeed conveyors, robotic cells, and automated material handling systems.
• Proficiency with Ethernet/IP, Profinet, EtherCAT, OPCUA, Modbus, serial, and similar industrial communication standards.

Preferred Skills

• Background as a commissioning-focused controls engineer at a system integrator or machine OEM - someone who has both written machine code and accepted other people’s.
• Robotics & Vision Systems: Working experience with multi axis robotic systems (Fanuc, Kuka, ABB) and machine vision platforms (Cognex, Keyence).
• Experience in heavy industrial, greenfield, chemical, or metallurgical manufacturing environments.
• Experience developing SCADA applications in Ignition, FactoryTalk, Wonderware, or similar platforms.
• AGV integration experience.
• Familiarity with Python, C++, or other high-level languages for automation or data analytics.
• Experience in regulated industries or such as Defense, Aerospace, or Automotive or GAMP 5 / computer system validation exposure.