Senior Automation Controls Engineer

Senior Automation & Controls EngineerOur growing client in Hudson County, NJ is hiring a Senior Automation & Controls Engineer who will lead the design and deployment of advanced automation solutions in a high-volume, high-complexity manufacturing environment. This engineer will drive large-scale automation initiatives that enhance efficiency, scalability, quality, and reliability across manufacturing operations. The position requires experience in mechatronic system design, robotics integration, PLCs, vision systems, and data analytics, with strong collaboration across cross-functional engineering teams.Responsibilities· Lead and contribute to manufacturing transformation initiatives focused on risk analysis, quality, and continuous improvement· Develop and implement automation, metrology, inspection, and predictive analytics systems that support a smart factory vision· Support NPI by building scalable automation strategies aligned with product roadmaps· Design automated assembly and test equipment for components such as PCBs, power modules, and cooling systems· Embed DFM and DFA principles into product development and translate PFMEA outputs into robust process controls· Develop integrated mechatronic systems using robotics, sensors, actuators, PLCs, vision systems, and motion control· Use data-rich environments and tools to drive improvements in yield, reliability, cycle time, and throughput· Evaluate, specify, validate, and install automation solutions with external equipment vendors· Lead tool qualification, process documentation, and operator training· Apply SPC, FMEA, DOE, and other analytical tools to improve manufacturing performance· Implement automated inspection and test systems to ensure product quality· Maintain compliance with safety and industry standards while generating clear documentation and training materialsRequirements· Bachelor's degree in Engineering, Computer Science, Data Science, or related field; MBA a plus· 6+ years in high-volume manufacturing environments· Strong foundation in statistical and analytical methodologies (regression, DOE, SPC, PFMEA, Gauge R&R, etc.)· Proficiency with analytical tools such as Minitab, JMP, Python, R, or SQL· Proven success driving improvements in yield, reliability, and process robustness· Background in electronics assembly, PCBA, servers, aerospace, medical devices, automotive, or similar high-reliability sectors· Proficiency in CAD tools and automation platforms (SolidWorks, AutoCAD, Siemens, Allen-Bradley, etc.)· Hands-on experience with PLC programming, robotics integration, and industrial sensors· Familiarity with MES systems and automation scripting (Python, SQL)· Exposure to AI/ML applications for predictive analytics or anomaly detection a plusBenefit OfferingsPTO/Holiday pay, Medical, dental, vision, term life and AD&D insurance, long-term disability, employee assistance program, and a 401k plan.