Sr. Controls Engineer

Job Description

Job Description

Company Summary

We are a global company of problem solvers, collaborators, and innovators with platforms in HVAC and Detection & Measurement. We build innovative solutions that enable a safer, more efficient, and sustainable world.

Job Summary As a Senior Automation Engineer

You will play a critical role in defining, developing, and deploying automation strategies across multiple manufacturing facilities to improve safety, quality, and productivity. The role focuses on robotic welding cells, automated material handling systems, and the integration of metal fabrication equipment with enterprise systems such as SAP. You will work cross-functionally with manufacturing, controls, IT, quality, and external suppliers to deploy scalable automation solutions from concept through production. This is an internal-facing role with significant vendor collaboration, supporting the broader HVAC segment amid strong growth and major manufacturing technology investments.

Responsibilities

• Automation System Design and Implementation : Design, specify, and implement automated manufacturing systems including robotic welding cells, part handling automation, and auxiliary equipment. Lead projects from concept through installation, commissioning, and production handoff. Support robot programming, end-of-arm tooling (EOAT), fixturing, and cell safety design.
• PLC Programming and Controls Integration : Design, program, and troubleshoot PLC-based control systems. Integrate PLCs with robots, weld power supplies, safety systems, vision systems, and material handling equipment. Develop and support HMI interfaces, standardized control architectures, naming conventions, alarms, and documentation.
• Robotic Welding and Fabrication Automation : Lead technical design and deployment of robotic welding systems. Establish standard robotic cell architectures, tooling concepts, and programming best practices. Serve as a technical mentor and escalation point for plant teams.
• Manufacturing Software and Systems Integration : Support integration with ERP systems, define standards for machine connectivity, job routing, recipe management, and production data collection. Collaborate with IT on industrial networks
• Continuous Improvement, Safety, and Support : Identify automation improvements for throughput, labor reduction, ergonomics, and safety. Troubleshoot complex issues involving PLC logic, robots, sensors, drives, and networks. Ensure compliance with machine and electrical safety standards

Requirements

• Bachelor's degree in Electrical, Controls, Mechatronics, Manufacturing, or a related engineering field.
• Minimum 5–10 years of experience in automation engineering, controls engineering, or manufacturing engineering with a strong automation focus.
• Hands-on experience programming and troubleshooting PLCs
• Ability to read, modify, and write ladder logic.
• Experience integrating PLCs with robots, HMIs, sensors, VFDs, safety systems, and industrial networks.
• Hands-on experience in manufacturing environments involving metals, fabricated components, or complex assemblies.

Preferred Requirements

• Experience with industrial robots, including programming and EOAT.
• Familiarity with custom automation/equipment solutions, robotics, HMI design, sensors/probes, machine monitoring, and safety systems.
• Experience designing or contributing to automation strategies, including material handling, gantry/pick-and-place, AGVs, welding, and assembly automation.
• Knowledge of lean manufacturing principles, continuous improvement tools, and structured problem-solving.
• Familiarity with ERP systems, 2D/3D CAD, and manufacturing layouts.
• Strong project management, analytical, organizational, and communication skills.
• PLC, robotics, or machine safety certifications are a plus.

Compensation/Benefits

• Base salary range: $102,000 – $156,000
• 10% annual bonus
• Strong work-life balance emphasized across facilities.
• Company travel card for business expenses (flights, hotels, rental cars, meals based on actual spend).

Location

• Preferred : Kansas City area
• Work Arrangement : Hybrid — Monday and Friday work-from-home when not traveling; generally on-site the rest of the week.
• Travel : 25–40% (typically 1–2 weeks per month), primarily across the US and sometimes Canada (Montreal, Toronto, Huntsville, Akron, Nashville, Chicago, California).