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.
• Own and evolve the site controls standard: code architecture, state machines, alarm and HMI conventions.
• Author the controls specification issued with every OEM equipment package and build the templates and code libraries that let area engineers and integrators execute consistently.
• Own the ISA-88 physical and procedural models; execute the batch-engine placement study (PLC-resident vs. supervisory vs. MES-driven), decision, and implementation.
• Define safety PLC and functional safety conventions (ISO 13849 performance levels, SIL-rated loops) with EHS and equipment vendors.
• Support 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 (SCADA).
• Own the controller-side data interface - exposed tags, handshakes, and the phase-logic contract - to the supervisory layers
• Review vendor electrical schematics, controls architectures, and PLC/HMI logic.
• Hold code review and acceptance authority for all delivered OEM PLC code.
• Serve as a senior-level escalation point for diagnosing complex automation issues involving networks, motion systems, instrumentation, and industrial communication protocols.
• Analyze OEE, downtime data, and SCADA/MES insights to identify and implement automation improvements that increase throughput, safety, and reliability.

Qualifications

• Bachelor’s or Masters degree in electrical engineering, Automation Engineering, Mechatronics, or related field with 8+ 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 authorship of controls standards, specifications, or code libraries used by other engineers and vendors.
• ISA-88 batch control: physical and procedural models, phase logic design, equipment/recipe separation.
• Deep understanding of servos, VFDs, highspeed conveyors, robotic cells, and automated material handling systems.
• Safety PLC programming competence and ISO 13849 / IEC 62061 interlock design judgment with the discipline to accept, reject, and defend decisions to OEMs with varying standards.
• Proficiency with Ethernet/IP, Profinet, EtherCAT, OPCUA, Modbus, serial, and similar industrial communication standards.

Physical and Environmental Requirements

• The position requires regular presence on the production floor and the ability to navigate all areas of the facility.
• Candidates must be able to climb stairs, stand and walk for extended periods, and work in environments that may be hot, humid, or noisy.
• The role also requires the use of personal protective equipment, including respirators, and adherence to all applicable safety policies, procedures, and regulatory requirements.