Senior Controls Engineer

Senior Controls EngineerWe are seeking a highly skilled and experienced Senior Controls Engineer with a strong background in industrial automation and a deep expertise in CoDeSys for PLC programming. The successful candidate will play a critical role in the design, development, implementation, and commissioning of complex control systems for our products/systems/manufacturing processes. This role requires a hands-on approach, strong problem-solving skills, and the ability to lead technical initiatives while mentoring junior engineers, all with a keen understanding of manufacturing principles and operational efficiency.Key Responsibilities:System Design & Architecture:Lead the conceptualization, design, and specification of complex control systems, including hardware selection (PLCs, HMIs, drives, sensors, actuators) and network architecture.Develop detailed electrical schematics, I/O lists, and wiring diagrams in collaboration with electrical engineers.Define control strategies, safety interlocks, and operational sequences, always considering manufacturing process flow, cycle time optimization, and overall equipment effectiveness (OEE).CoDeSys Programming & Development (Core Responsibility):Expertly program, test, and debug PLC logic using CoDeSys (IEC 61131-3) in various languages (ST, FBD, LD, SFC).Develop and implement reusable CoDeSys libraries, function blocks, and structured text routines, ensuring solutions are robust, maintainable, and scalable for production environments.Integrate and configure various fieldbus protocols (e.g., EtherCAT, PROFINET, Modbus TCP/IP, CANopen) within the CoDeSys environment.Develop and integrate HMI/SCADA applications using CoDeSys visualization or other compatible platforms, prioritizing operator usability, process visibility, and diagnostic capabilities for manufacturing personnel.Commissioning & Troubleshooting:Lead the on-site commissioning, testing, and tuning of control systems, ensuring optimal performance and adherence to specifications, with a focus on achieving production targets and minimizing downtime.Perform advanced troubleshooting and diagnostics of complex hardware and software issues, often under pressure in a live manufacturing environment.Collaborate with mechanical, electrical, and software engineers to resolve system integration challenges, understanding their impact on the manufacturing line.Documentation & Standards:Create and maintain comprehensive technical documentation, including functional specifications, design documents, test plans, and as-built drawings, which are essential for long-term manufacturing support and maintenance.Ensure all control system designs and implementations comply with relevant industry standards (e.g., UL, CE, NFPA, ISO, ANSI) and manufacturing specific regulations.Adhere to established coding standards and best practices for CoDeSys development.Project Leadership & Mentorship:Lead technical aspects of projects, including scope definition, scheduling, and resource allocation, considering production timelines and resource availability within a manufacturing context.Provide technical guidance and mentorship to junior controls engineers, fostering their development in CoDeSys and control system design with an emphasis on practical manufacturing applications.Participate in design reviews and provide constructive feedback.Continuous Improvement & Manufacturing Optimization:Stay abreast of new technologies, industry trends, and best practices in industrial automation and CoDeSys, specifically those applicable to improving manufacturing processes and efficiency.Proactively identify opportunities for process improvement, standardization, cost reductionYour Profile• Education: Bachelor's degree in Electrical Engineering, Mechatronics Engineering, Computer Engineering, or a closely related engineering discipline from an accredited university. Master's degree a plus.• Experience: Minimum of 7+ years of progressive experience in industrial control systems design, programming, and commissioning, with a significant portion in manufacturing or production environments.• Minimum of 3+ years of dedicated, hands-on experience programming and developing complex applications with CoDeSys (all versions/compatible platforms are valuable) for industrial machinery or production lines.• Proven experience leading technical aspects of control system projects, from concept to production readiness.• Technical Skills (Must-Haves): Expert-level proficiency in CoDeSys (IEC 61131-3) programming.• Strong understanding of industrial networking protocols (e.g., EtherCAT, PROFINET, Modbus TCP/IP, CANopen, Ethernet/IP).• Proficient with HMI/SCADA development and integration, with an emphasis on intuitive operator interfaces and robust data acquisition for manufacturing analytics.• Solid understanding of electrical control panel design principles and safety standards (e.g., NFPA 79, UL 508A, EN ISO 13489, IEC 60204), and their application in a manufacturing plant.• Experience with industrial safety systems (e.g., safety PLCs, light curtains, emergency stops) as applied to production equipment and personnel safety.• Familiarity with CAD software for electrical design (e.g., AutoCAD Electrical, EPLAN).• Ability to read and interpret complex electrical schematics and mechanical drawings.• Demonstrated understanding of manufacturing processes, including but not limited to: material handling, assembly, machining, packaging, process control, and quality inspection.• Knowledge of key manufacturing metrics such as OEE, cycle time, throughput, and their impact on control system design.• Soft Skills: Excellent analytical and problem-solving abilities, particularly in diagnosing and resolving production issues.• Strong written and verbal communication skills, able to convey complex technical information to production, maintenance, and management teams.• Ability to work independently and as part of a multidisciplinary team, including collaboration with production operators and maintenance technicians.• Demonstrated leadership potential and ability to mentor.• Strong attention to detail and commitment to quality.• Ability to manage multiple priorities and meet deadlines in a fast-paced manufacturing environment.