Senior Control Engineer

Job Title: Senior Manufacturing Controls Engineer

Employment Type: Direct Hire

About the Role:

We are seeking an experienced Senior Manufacturing Controls Engineer to support the design, implementation, and optimization of manufacturing automation and control systems in a fast-paced production environment. This role is responsible for improving manufacturing efficiency, reducing downtime, troubleshooting equipment and process issues, and supporting new equipment installations and process improvements.

• Design, develop, and optimize control systems for manufacturing equipment and automated production processes.
• Identify manufacturing process issues and implement corrective actions through testing, evaluation, troubleshooting, and analysis.
• Develop and implement automation solutions to improve production efficiency, reliability, and cost performance.
• Troubleshoot and resolve electrical, instrumentation, PLC, HMI, servo motor, stepper motor, and sensor-related production equipment issues.
• Develop and document functional specifications for manufacturing systems, including hardware and software integration.
• Establish and maintain sustainable plant-wide standards for automation controls, PLCs, HMIs, industrial networking, and process monitoring systems.
• Collaborate with Manufacturing Engineering, Maintenance, Operations, and Quality teams to implement process improvements and equipment upgrades.
• Support equipment uptime initiatives by diagnosing and resolving downtime related to motor-driven control systems and automation components.
• Create and maintain electrical schematics and oversee the development of industrial electrical control panels compliant with NFPA
  79, NEC, and UL508A standards.
• Participate in new equipment process (NEP) projects, including equipment replacements, upgrades, installations, and process optimization initiatives.
• Program and integrate PLCs, HMIs, servo systems, machine vision systems, sensors, and industrial communication protocols.
• Develop and support Human-Machine Interfaces (HMIs) to improve operator interaction with manufacturing equipment.
• Support machine safety and fail-safe control system designs in compliance with ISO, NFPA, NEMA, NEC, and ANSI standards.
• Provide technical training, guidance, and support to manufacturing, maintenance, and operations teams.

• Bachelor’s degree in Electrical Engineering, Controls Engineering, or a related technical field required.
• 5+ years of experience in controls engineering, automation, electrical design, troubleshooting, and machine commissioning required.
• Strong experience with Rockwell/Allen-Bradley PLCs and HMI development required.
• Proficiency programming and troubleshooting PLCs, SCADA systems, HMIs, industrial networking, and automation controls.
• Experience integrating servo systems, stepper motors, machine vision systems, sensors, and related automation technologies into manufacturing equipment required.
• Strong understanding of industrial communication protocols including Serial, OPC, and FTP.
• Experience designing electrical control systems, overload protection circuits, and industrial control panels.
• Proficiency with Electrical AutoCAD and/or Solid Works Electrical required.
• Knowledge of machine safety standards and fail-safe control system design including ISO, NFPA, NEMA, NEC, and ANSI standards.
• Experience with industrial robots and repeatable automation programming architecture preferred.
• Strong troubleshooting, analytical, and root cause problem-solving skills.
• Experience with Statistical Process Control (SPC), data analysis, Lean Manufacturing, Six Sigma, or continuous improvement methodologies preferred.