Senior Controls Engineer

Senior Controls Engineer

Location: Sterling, MA

About the Role

A growing automation systems integrator specialising in custom machine building and systems integration is seeking a Senior Controls Engineer to anchor its engineering team in Sterling, MA. This is a technical leadership role suited to an experienced professional capable of owning complex projects end-to-end-driving system architecture, programming, and commissioning while mentoring junior engineers and acting as a trusted technical advisor to customers.

The ideal candidate brings strong hands-on expertise, sound judgement in ambiguous situations, and the ability to lead through influence within a lean, fast-paced environment.

Key Responsibilities

• Technical Leadership: Serve as the lead engineer on complex, multi-disciplinary projects, owning architecture decisions and guiding the technical approach from concept through commissioning.
• Advanced Programming: Design and develop PLC, HMI, safety controller, motion control, and vision system applications using platforms such as Allen-Bradley, Siemens, CoDeSys, Mitsubishi, Omron, Bosch, Cognex, Keyence, and SICK. Lead SCADA and plant-level visualisation development using Ignition.
• System Architecture & Electrical Design: Define control system architecture and lead the development of electrical schematics and control panel layouts in 2D CAD, ensuring adherence to best practices.
• Standards & Best Practices: Establish and maintain engineering standards, reusable code libraries, and documentation templates to improve quality and consistency.
• System Integration: Oversee integration of control systems into manufacturing environments, coordinating across mechanical, electrical, and software teams to ensure performance and reliability.
• Commissioning & Troubleshooting: Lead on-site system startup, diagnostics, and advanced troubleshooting to resolve complex technical challenges.
• Mentorship & Support: Mentor junior engineers, conduct design and code reviews, and provide technical guidance to internal teams and customers.
• Project Execution: Manage project timelines, budgets, and vendor relationships, ensuring projects are delivered on time and within scope.
• Compliance & Safety: Ensure all systems meet regulatory and safety standards, including UL 508A and industrial electrical requirements.

Qualifications

• Education: Bachelor's degree in Electrical Engineering, Computer Science, or a related technical field.
• Experience: Minimum of 8 years' experience in controls or electrical engineering within industrial, manufacturing, or custom machine-building environments, with a proven track record of leading projects from concept through commissioning.
• Technical Expertise: Strong PLC programming experience and hands-on system configuration. Experience with Ignition SCADA and Siemens platforms preferred; familiarity with Allen-Bradley, CoDeSys, or Mitsubishi is also valuable. Background in motion control, machine vision, sensors, and data acquisition is expected.
• Documentation & BOM Management: Expertise in managing structured BOMs and complete electrical drawing packages throughout the project lifecycle.
• Vendor & Procurement Experience: Ability to evaluate vendor quotes, source custom components, and manage supplier relationships.
• Project Delivery: Demonstrated success delivering projects on time and within budget in a project-based or job-shop environment, including managing change orders.
• Work Style: Comfortable working in a lean environment, taking full ownership, and handling multiple responsibilities. Experience with smaller integrators or custom machine builders is preferred.
• Communication: Strong communication skills with the ability to convey complex technical concepts clearly to varied audiences.

Platform Backing & Capabilities

The organisation operates as part of a broader automation platform, providing access to expanded resources and cross-functional expertise in panel fabrication, SCADA/MES, machine vision, and robotics. This structure enables engineers to deliver highly technical solutions across industries such as food & beverage, life sciences, aerospace, and defence.

Why Join

• Competitive salary with annual bonus potential and clear progression into technical leadership
• Collaborative, low-bureaucracy environment where engineers have strong ownership
• Exposure to a wide range of industries and custom machine applications
• A culture focused on quality, accountability, and continuous improvement
• Drive Innovation
• Collaborate Effectively