Sr. Controls Engineer

Sr. Controls Engineer

We are seeking a Sr. Controls Engineer to design, develop, and commission control systems for automated manufacturing equipment. The role focuses on delivering robust PLC and HMI solutions, integrating vision systems, and ensuring reliable operation of automated systems from concept through production. The Sr. Controls Engineer will lead technical controls work, troubleshoot complex system issues, and collaborate with cross-functional teams to achieve production, quality, and safety goals.

Key Responsibilities

• Lead design and development of PLC control systems using Allen-Bradley platforms (Studio 5000/RSLogix).
• Architect, configure, and deploy HMI solutions (FactoryTalk/PanelView or equivalent) for operator interfaces and diagnostics.
• Integrate and commission machine vision systems (e.g., Cognex, Keyence) for part detection, inspection, and guidance.
• Develop control system I/O lists, ladder logic, structured text, function block diagrams, and motion/servo control routines.
• Create and maintain electrical schematics, control wiring diagrams, and panel layouts in collaboration with electrical designers.
• Perform FAT/SAT, site commissioning, and hands-on troubleshooting to resolve complex hardware, software, and communication issues.
• Implement industrial network configurations (Ethernet/IP, DeviceNet, Modbus) and ensure reliable device communications and cybersecurity best practices.
• Work with mechanical, manufacturing, and quality teams to ensure controls meet functional requirements and production performance targets.
• Write clear technical documentation, test plans, and as-built drawings; train operators and maintenance personnel.
• Drive continuous improvement projects to increase equipment uptime, reliability, and efficiency; mentor junior engineers and technicians.
• Coordinate with vendors and integrators for procurement, acceptance testing, and support of control components and vision equipment.
• Ensure compliance with safety standards and company procedures during design, installation, and commissioning activities.

Qualifications

• 5+ years of direct experience designing, programming, and commissioning industrial control systems; prior senior-level responsibility preferred.
• Proven expertise with Allen-Bradley PLCs and related programming tools (Studio 5000, RSLogix).
• Hands-on experience with PLCs, HMIs (FactoryTalk/PanelView or similar), and industrial automation hardware.
• Experience integrating and commissioning vision systems (Cognex, Keyence, or similar) for inspection, guidance, and robotics applications.
• Strong understanding of automated systems, motion control, servo drives, and machine safety interlocks.
• Familiarity with industrial networks (Ethernet/IP, DeviceNet, Modbus) and PLC-to-device communications.
• Ability to read and produce electrical schematics, control panel layouts, and I/O documentation.
• Excellent troubleshooting skills with the ability to diagnose electrical, mechanical, and software causes of equipment failures.
• Strong communication and collaboration skills; experience leading cross-functional project teams.
• Willingness to travel to customer or plant sites for commissioning and support as required.

Benefits

Health, Vision, Dental, PTO, 401K, Paid Holidays

For this position you must be currently authorized to work in the United States. We do not sponsor for this position.