Senior Controls Engineer

Senior Controls EngineerPosition OverviewWe are seeking a Senior Controls Engineer to lead the design, implementation and commissioning of advanced industrial control systems for automated manufacturing equipment. The role focuses on developing robust PLC/HMI and motion control solutions, integrating robotics and vision systems, and delivering reliable SCADA and factory-floor automation that improve safety, quality and productivity. The ideal candidate combines hands-on technical expertise with project leadership and continuous improvement mindset.Key ResponsibilitiesLead design and development of control system architectures for machinery and production lines, including PLC, HMI, motion control and safety systems.Program, test and commission PLC and HMI applications (Rockwell ControlLogix/GuardLogix, Studio5000, Siemens, Omron and equivalents).Design and implement SCADA solutions and operator interfaces (FactoryTalk, other SCADA platforms) to provide real-time visibility and control.Integrate industrial robots and cell controllers (Fanuc, ABB, Motoman) using tools such as Roboguide and RobotStudio; coordinate robot safety and part handling routines.Implement machine vision solutions and integrate with PLCs/robotics for inspection and guidance tasks.Develop motion control, servo and encoder-based sequencing for high-speed, synchronized machinery.Perform electrical and control system design tasks using AutoCAD and electrical CAD packages; create wiring diagrams, I/O lists and panel layouts.Lead commissioning, FAT/SAT activities, on-site troubleshooting and root-cause analysis to bring equipment to reliable production.Execute systems integration across drives, motors, sensors, vision, safety and SCADA; validate communication over EtherNet/IP, Profinet, Modbus and other industrial networks.Author and maintain technical documentation: design packages, functional specifications, test plans, commissioning reports and SOPs.Mentor and coach junior engineers and technicians; provide technical leadership across multidisciplinary project teams.Drive continuous improvement initiatives: optimize code, reduce cycle times, improve OEE and implement preventive maintenance strategies.Use scripting and automation tools (Python, VBA) and modern AI-assisted tools (e.g., ChatGPT) to accelerate development, automate testing and improve diagnostics.Ensure designs and procedures comply with industry safety standards, local codes and internal quality systems.QualificationsBachelors degree in Electrical, Controls, Mechatronics or related engineering discipline (or equivalent experience).7+ years of controls engineering experience in industrial automation, machine design or manufacturing environments; experience as lead controls engineer preferred.Strong PLC programming skills with Rockwell ControlLogix/Studio5000 and GuardLogix; experience with Siemens and Omron PLC platforms a plus.Hands-on experience with Rockwell FactoryTalk, SCADA systems and HMI application development.Proven experience integrating industrial robots (Fanuc, ABB, Motoman) and using Roboguide and RobotStudio for offline programming and simulation.Practical knowledge of machine vision systems and integration with controls (Cognex, Keyence or similar).Expertise in motion control, servo drives, encoders and synchronized multi-axis systems.Competence in electrical schematics, panel layouts and AutoCAD/electrical CAD tools.Strong troubleshooting, commissioning and field support experience with FAT/SAT and site acceptance testing.Experience with scripting and automation (Python, VBA); comfortable leveraging AI tools like ChatGPT to improve productivity.Willingness to travel to customer sites for commissioning and support; valid drivers license.Benefits- Medical, Dental, Vision- Short and Long Term Disability - 401(k) with Company Match - Education reimbursement - PTO and Holidays - FSA