Senior Controls Engineer

Job Title:

Senior Controls Engineer

Job Description

The Senior Controls Engineer designs, develops, and deploys automated equipment across manufacturing and production environments. This role serves as a technical leader throughout the full project lifecycle, partnering with cross-functional teams and external suppliers to deliver compliant, reliable, and high-quality automation solutions. The engineer takes ownership from concept through commissioning, ensuring robust industrial control systems that support material handling, liquid filling, capping, labeling, and palletizing operations.

Responsibilities

+ Lead and support automation projects from concept through commissioning, including planning, design, programming, purchasing, integration, testing, and training.

+ Collaborate with internal manufacturing teams and external suppliers or integrators to develop user requirements specifications (URS), automation concepts, and high-level system architectures.

+ Support automated equipment used for material handling, liquid filling, capping, labeling, and palletizing to ensure reliable and efficient operation.

+ Design, program, and troubleshoot industrial control systems, including PLCs, robotics, HMIs, vision systems, motion control systems, and safety systems.

+ Participate in design reviews with contractors, engineering consultants, and project stakeholders, providing technical input, guidance, and clear project status updates.

+ Ensure supplier deliverables meet internal technical standards and applicable regulatory requirements.

+ Drive best practices across all project phases, including procurement, supplier design reviews, factory acceptance testing (FAT), site acceptance testing (SAT), equipment installation, and commissioning.

+ Support equipment debugging, startup, and commissioning activities to achieve stable and validated production performance.

+ Provide operator and maintenance training to ensure safe, efficient, and consistent use of automated equipment.

+ Contribute to continuous improvement initiatives by identifying opportunities to enhance automation performance, reliability, and safety.

Essential Skills

+ Bachelor's degree in Engineering, Mechatronics, Automation, or a related field with 5+ years of relevant experience, or a Master's degree with 2+ years of experience.

+ Strong proficiency in PLC programming, including ladder logic and structured text.

+ Hands-on experience with industrial automation components such as AC/DC drives, servo motors, HMIs, machine vision systems, and machine safety systems.

+ Experience supporting equipment installation, debugging, commissioning, and validation activities in manufacturing or production environments.

+ Strong written and verbal communication skills with the ability to clearly explain technical concepts to diverse stakeholders.

+ Proven ability to work effectively in a collaborative engineering team environment.

+ Continuous improvement mindset with strong analytical and problem-solving skills.

+ Demonstrated experience in controls engineering and automation, including PLC programming and system integration.

Additional

Skills & Qualifications

+

Experience with complex mechanical systems and exposure to CAD modeling.

+ Familiarity with Rockwell Automation PLCs and related platforms.

+ Experience working with industrial robotics in automated manufacturing environments.

+ Knowledge of Cognex or similar machine vision systems.

+

Experience with PLC and SCADA system integration.

+ Basic understanding of industrial networking concepts, including TCP/IP and Ethernet/IP fieldbus architectures.

+ Background in automation, controls engineering, and SCADA systems.

+ Ability to work independently while coordinating with suppliers, integrators, and internal stakeholders.

+ Willingness to travel up to approximately 15% of the time to domestic manufacturing and supplier sites.

Work Environment

This role is fully on-site within a manufacturing and production environment focused on automated equipment and industrial control systems. The position involves regular interaction with automated machinery, including PLC-based systems, robotics, HMIs, motion control, and machine vision equipment. The engineer collaborates closely with cross-functional teams, contractors, and external integrators, and participates in activities such as factory acceptance testing (FAT), site acceptance testing (SAT), equipment installation, debugging, and commissioning.

Up to approximately 15% annual travel to domestic manufacturing and supplier sites is expected to support project execution and on-site integration. The work environment emphasizes safety, adherence to technical and regulatory standards, and a culture of continuous improvement and collaboration.

Job Type & Location

This is a Contract to Hire position based out of Hebron, KY.

Pay and Benefits

The pay range for this position is $48.08 - $48.08/hr.

Eligibility requirements apply to some benefits and may depend on your job classification and length of…