Sr. Controls Engineer

We are looking for a hands-on Controls Engineer with strong experience in industrial automation and control systems. This individual will play an active role on the manufacturing floor, supporting the design, programming, commissioning, and optimization of automation systems used throughout production. The ideal candidate will have practical expertise with PLC programming, HMI development, and industrial controls. Experience working with SCADA platforms and integrating advanced manufacturing equipment is highly desirable.

Success in this role requires a solid foundation in controls engineering, the ability to troubleshoot and resolve automation issues, and a strong commitment to maintaining a safe operating environment.

• Design, program, test, and commission PLC-based automation systems supporting manufacturing operations.
• Develop, modify, and maintain HMI and SCADA applications used for equipment operation and process visualization.
• Integrate instrumentation, sensors, actuators, and other field devices to improve equipment performance and process reliability.
• Prepare and maintain electrical drawings, control narratives, I/O documentation, and other technical records.
• Assist with equipment installation, startup activities, and commissioning of new automation systems.
• Troubleshoot PLCs, HMIs, and related control systems to quickly resolve production issues and reduce equipment downtime.
• Perform routine updates, preventive maintenance, and enhancements to automation hardware and software.
• Maintain proper documentation and version control for all control system changes and software revisions.

• Design and maintain control systems that comply with applicable safety regulations and recognized industry standards, including OSHA and ISO requirements.
• Implement and support machine safety functions such as emergency stop circuits, safety interlocks, and guarding systems.
• Participate in safety audits, inspections, and continuous improvement initiatives to identify and reduce operational risks.
• Support workplace organization and safety initiatives through established housekeeping and continuous improvement practices.

• Bachelor's degree in Electrical Engineering, Controls Engineering, Mechatronics, Instrumentation, or a closely related engineering discipline required. A Master's degree is preferred.
• Minimum of five years of progressive experience designing, programming, commissioning, and supporting industrial automation and control systems within a manufacturing environment.
• Demonstrated experience leading automation projects through the full lifecycle, from initial design through startup and production support.

• Strong PLC programming experience with major platforms including Allen-Bradley/Rockwell, Siemens, and Beckhoff.
• Proficiency with Structured Text, Ladder Logic, and Function Block programming.
• Experience developing HMI and SCADA applications using platforms such as Factory Talk View, Wonderware, WinCC, or similar software.
• Knowledge of industrial networking and communication protocols including Ether Net/IP, PROFINET, Modbus, and EtherCAT.
• Working knowledge of electrical systems, motor controls, instrumentation, and industrial electrical safety standards.
• Ability to develop and maintain control documentation including electrical schematics, I/O lists, control narratives, and related engineering documentation.
• Experience integrating automation systems with Manufacturing Execution Systems (MES) and plant information systems is required.

• Thorough understanding of industrial electrical safety practices, machine safety principles, and applicable regulatory requirements governing automated manufacturing systems.

• Strong interpersonal and communication skills with the ability to collaborate effectively across production, maintenance, engineering, and external vendors.
• Proven analytical and troubleshooting abilities with a hands-on approach to identifying root causes and implementing practical automation solutions in a fast-paced manufacturing environment.