Senior Controls Engineer

An established U.S. engineering and manufacturing organization is seeking a senior-level controls professional to lead complex automation projects from initial design through onsite startup. This position is intended for an engineer who can take ownership of complete controls packages, solve difficult system‑integration problems, and work effectively across engineering, operations, suppliers, and customers.

• Develop, program, test, and troubleshoot sophisticated PLC and HMI applications using Rockwell Automation / Studio 5000 platforms.
• Lead field installation, system checkout, commissioning, and production ramp‑up activities.
• Create electrical control‑system designs, including panel layouts, power distribution, safety circuits, device selection, and network architecture.
• Select and size motors, servo systems, variable‑frequency drives, sensors, actuators, and related automation hardware.
• Integrate industrial robots, machine vision, motion control, tooling, conveyors, safety devices, and other production equipment into a unified system.
• Establish controls architecture for new equipment and production lines, including projects with limited existing standards or legacy designs.
• Diagnose system‑level issues, determine root causes, and implement durable corrective actions.
• Coordinate technical work with internal disciplines, customers, equipment suppliers, and subcontractors.
• Apply relevant machine and electrical safety practices, including UL 508A, NFPA 79, and ISO 13849 considerations.

• Approximately 5-15 years of controls, electrical, or automation engineering experience supporting complex machinery or manufacturing systems.
• Demonstrated success carrying greenfield automation projects from concept and design through installation, validation, commissioning, and production use.
• Advanced hands‑on experience with Allen‑Bradley PLCs, HMIs, drives, and motion‑control systems.
• Strong proficiency with AutoCAD Electrical and the ability to produce complete, accurate electrical documentation.
• Thorough knowledge of control‑panel design, electrical schematics, industrial networking, and machine‑safety systems.
• Experience integrating robotics and vision systems with PLC‑controlled equipment.
• Ability to work independently, manage competing technical priorities, and communicate clearly with both technical and nontechnical stakeholders.
• Willingness to travel to customer or project locations for installation, troubleshooting, and commissioning as needed.

• Experience with FANUC, ABB, KUKA, or comparable industrial robot platforms, including path teaching and cycle‑time improvement.
• Exposure to SCADA, manufacturing data collection, or higher‑level plant information systems.
• Experience mentoring engineers or serving as the controls lead for multidisciplinary projects.
• Familiarity with regulated, defense‑related, or other high‑compliance manufactur