Senior Controls Engineer

Job Title

Senior Controls Engineer

The Senior Controls Engineer will design, program, and integrate custom automated machinery from initial concept through final installation and commissioning. This role works closely with a team of controls engineers and collaborates with electrical and mechanical engineering disciplines to deliver complete, robust control systems. The position involves customer interaction, on‑site support, and the opportunity to take technical lead responsibilities, including mentoring and guiding project work, while consistently operating at a Senior engineering level.

• Design, program, and integrate control systems for custom machines based on customer specifications, from concept through final acceptance.
• Develop and troubleshoot PLC programs, primarily using Rockwell/Allen‑Bradley platforms, and support additional platforms such as Siemens, GE, and Omron as needed.
• Configure, program, and commission industrial robots, with a primary focus on Fanuc robots and additional work with Nachi, ABB, and Motoman systems.
• Implement and validate machine safety features within control and robotic systems to ensure safe and reliable operation.
• Perform hardware design using AutoCAD Electrical, including creation and modification of electrical schematics and panel layouts.
• Design and interpret hydraulic and pneumatic system schematics and integrate these systems into the overall machine control architecture.
• Collaborate closely with electrical and mechanical engineers to ensure seamless integration of controls, hardware, and mechanical components.
• Provide on‑site support at customer facilities for installation, start‑up, debugging, and commissioning of automated equipment.
• Troubleshoot and resolve electrical, controls, and robotic issues both remotely and on‑site to minimize downtime and ensure customer satisfaction.
• Interact with customers professionally to gather requirements, provide technical updates, and support acceptance testing.
• Lead projects or portions of projects when appropriate, including mentoring team members and coordinating technical activities.
• Document control system designs, programs, and changes clearly and accurately for internal use and customer handover.
• Support continuous improvement efforts by refining standard designs, templates, and best practices for controls and automation projects.

• 7+ years of experience in controls engineering, automation, or a closely related field.
• Strong expertise in PLC programming and troubleshooting, with significant experience on Rockwell/Allen‑Bradley platforms.
• Hands‑on experience with robotic programming and integration, primarily with Fanuc robots and additional exposure to ABB systems.
• Proficiency with AutoCAD Electrical for hardware design, including creation and interpretation of electrical schematics.
• Ability to design, read, and troubleshoot hydraulic and pneumatic schematics and integrate these systems into control architectures.
• Solid understanding of control systems, electrical engineering principles, and industrial automation practices.
• Experience with OEM environments, including work on equipment for major automotive manufacturers such as Ford and GM.
• Ability to diagnose and resolve complex electrical, controls, and robotic issues in a fast- paced environment.
• Strong communication skills to interact effectively with customers, team members, and cross-functional engineering disciplines.
• Willingness and ability to travel approximately 20-30%, including primarily local travel and occasional international trips.

• Experience with Siemens, GE, and Omron PLC platforms is beneficial.
• Familiarity with additional robotic platforms such as Nachi and Motoman is a plus.
• Background in electrical engineering, control systems, or a related technical discipline (degree not required).
• Prior experience working with or for OEMs in automotive or similar high-volume manufacturing industries.
• Demonstrated ability to lead projects or technical work streams and mentor other engineers.
• Comfort working both independently and as part of a collaborative engineering team.
• Strong organizational…