Senior Controls Engineer

Sr. Controls EngineerPosition OverviewWe are seeking a Senior Controls Engineer to lead the design, development, integration, and commissioning of machine and process control systems. The role focuses on PLC programming, HMI development, robotics integration, automation architecture, and vision system implementation to deliver reliable, scalable manufacturing and material handling solutions. The Senior Controls Engineer will work closely with mechanical, electrical, and software teams, interface with customers during commissioning, and drive continuous improvement and technical excellence across projects.Key ResponsibilitiesDesign and develop PLC programs and HMI applications for complex automation systems using industry best practices and standards.Integrate and program robotics systems (industrial manipulators, end-of-arm tooling, robot controllers) into automated cells and production lines.Develop and implement machine vision and inspection solutions, including camera selection, lighting, vision tool development, and integration with PLC/robotics controls.Lead controls system architecture and integration activities across electrical, mechanical, and software disciplines to ensure seamless operation and safety compliance.Perform on-site commissioning, start-up, debugging, and performance tuning of automated systems; work directly with customers and operators to validate functionality and transfer knowledge.Create and maintain clear documentation: control narratives, I/O lists, wiring diagrams, PLC/HMI source code, software revision control, and FAT/SAT test plans and reports.Support risk assessments, safety system design (E-stops, safety PLCs, light curtains), and adherence to relevant codes and standards (e.g., IEC, NFPA, ISO).Mentor junior controls engineers and technicians, lead technical reviews, and contribute to project planning, estimation, and continuous improvement initiatives.Troubleshoot complex electrical, control, and software issues remotely and on-site, providing timely root-cause analysis and corrective actions.Collaborate with suppliers and integrators for selection and procurement of control components, robotics, vision hardware, and custom automation equipment.QualificationsBachelors degree in Electrical, Control, Mechatronics, or related engineering discipline (or equivalent experience).3+ years of experience in industrial controls engineering with demonstrable experience in PLC programming (e.g., Rockwell/AllenBradley, Siemens, or similar).Proven experience developing HMI/SCADA applications and operator interfaces.Hands-on experience integrating and programming industrial robots and robot controllers (ABB, FANUC, KUKA, Yaskawa, etc.).Practical experience with automation system integration and commissioning of manufacturing equipment and production lines.Experience designing and deploying vision systems for inspection, guidance, or identification tasks (e.g., Cognex, Keyence, Basler).Strong troubleshooting and commissioning skills, including on-site startup and customer-facing problem solving.Familiarity with industrial communications and protocols (EtherNet/IP, Profinet, Modbus, OPC UA).Excellent documentation, verbal, and written communication skills; ability to produce clear test plans, reports, and control narratives.Ability to travel to customer sites for commissioning and support as required.Nice to have: experience with FEA for mechanical/structural evaluation and CAD familiarity (SolidWorks, AutoCAD) to collaborate effectively with mechanical engineering teams.Relevant certifications (PLC vendor courses, robotics programming, or certifications in safety standards) are a plus.BenefitsHealth/Vison/Dental/Life401kBonus OpportunitiesPTORelocation Assistance