Senior Controls Engineer

Job Description

Job Description

Senior Controls Engineer

Position Overview

We are seeking a Senior Controls Engineer to design, develop, and evolve industrial control systems for advanced machine platforms. This role combines hands-on controls development with system architecture, hardware selection, R&D, and high-level technical troubleshooting.

You will take control systems from concept through commissioning—defining architecture, selecting and validating hardware, developing control software, integrating motion and communication systems, and ensuring performance, reliability, and scalability.

You will also help standardize control architectures to enable reuse across machines and support future automation platforms.

Key Responsibilities

Controls Development & System Architecture

• Design and develop industrial control systems for new machines, platform migrations, and feature enhancements.
• Architect full control solutions including PLCs, motion systems, drives, sensors, I/O, and industrial networks.
• Develop, test, and maintain control software for complex automated systems.
• Translate machine performance requirements into robust control strategies.
• Debug and resolve system-level software and controls issues.
• Develop reusable, standardized control architectures across platforms.
  

Hardware Ownership & Lifecycle Management

• Select and validate controllers, drives, motors, sensors, and related hardware.
• Ensure hardware meets performance, reliability, maintainability, and lifecycle requirements.
• Manage component obsolescence and develop replacement strategies.
• Evaluate and integrate next-generation hardware and technologies.
• Collaborate with suppliers and internal teams on system validation.
  

R&D & Continuous Improvement

• Lead or support R&D initiatives for new platforms and automation technologies.
• Improve internal standards, tools, and control system infrastructure.
• Drive continuous improvement of control architectures and engineering practices.
• Apply field and commissioning feedback to future designs.
  

Commissioning & Technical Support

• Support commissioning and validation of control systems.
• Act as escalation point for complex field service issues.
• Perform root-cause analysis across controls, motion, hardware, and communications.
• Provide technical guidance to engineering and service teams.

Required Qualifications

• 8+ years designing, developing, and commissioning industrial control systems or similar automation systems.
• Experience delivering control systems from concept through commissioning.
• Strong background in closed-loop control, motion control, and real-time/embedded systems.
• Ability to translate performance requirements into control system design.
• Experience designing full control architectures (hardware, software, motion, I/O, networks).
• Experience selecting and validating industrial hardware (PLCs, drives, motors, sensors, actuators).
• Experience with industrial networks such as PROFINET, EtherCAT, or CANopen.
• Strong troubleshooting skills in complex electromechanical systems.
• Experience considering reliability, maintainability, and obsolescence in design decisions.
• Ability to independently lead complex controls projects.

Preferred Qualifications

• Siemens experience (TIA Portal, S7-1500/1200, SINAMICS).
• Experience building modular or standardized control architectures.
• R&D experience in automation, motion control, or machine development.
• Field service or manufacturing support experience.
• Experience with hardware lifecycle management.

What Success Looks Like

Success in this role means bridging system-level thinking with hands-on execution. You understand not just how a control system works, but why a given architecture is optimal.

You build control systems that are precise, reliable, maintainable, and scalable across current and future machine platforms.

Tuftco is an equal opportunity employer and is committed to providing equal employment opportunities to all applicants and employees. Employment decisions are made without regard to race, color, religion, sex, sexual orientation, gender identity, national origin, age, disability, genetic information, veteran status, or any other characteristic protected by applicable federal, state, or local law.