Senior Controls Engineer

Location: Newaygo

Job Title:

Senior Controls Engineer

Job Description

The Senior Controls Engineer serves as a technical leader responsible for designing, implementing, supporting, and improving advanced automation systems across manufacturing operations. This role focuses on intelligent systems, automated equipment, connected manufacturing, and innovative technologies that enhance safety, efficiency, reliability, and performance. The Senior Controls Engineer leads projects from concept through commissioning, establishes engineering standards, troubleshoots complex production issues, and drives Industry 4.0 and Industrial IoT initiatives while partnering closely with operations, maintenance, engineering, IT, and external vendors to improve manufacturing performance and reliability.

Responsibilities

+ Lead controls engineering efforts for new equipment, automation upgrades, and existing production systems across manufacturing operations.

+ Design, program, commission, and troubleshoot PLC, HMI, SCADA, vision, and robotic systems to support safe and efficient production.

+ Drive root cause analysis and implement corrective actions for issues impacting safety, quality, uptime, and productivity.

+ Define project scopes, technical requirements, and acceptance criteria for automation and controls projects.

+ Support equipment startups, installations, and ongoing production operations, ensuring stable and reliable performance.

+ Develop and maintain controls standards, documentation, and best practices for automation systems.

+ Lead system architecture reviews and equipment standardization initiatives to ensure consistency and scalability.

+ Manage controls documentation, backups, version control, and lifecycle planning for automation assets.

+ Evaluate and recommend improvements to automation hardware and software platforms to enhance performance and maintainability.

+ Lead smart manufacturing and Industrial IoT initiatives that enable connected manufacturing and data-driven decision making.

+ Implement solutions involving data collection, edge computing, industrial networking, and integration with enterprise systems.

+ Support technologies such as OPC UA, MQTT, MES connectivity, data historians, and other digital manufacturing tools.

+ Develop procedures that support scalable deployment and long-term sustainability of connected manufacturing systems.

+ Ensure cybersecurity, compliance, and proper management of manufacturing data in operational technology environments.

+ Lead initiatives focused on reducing downtime and improving Overall Equipment Effectiveness (OEE).

+ Drive projects that improve reliability, reduce cost, and increase operational efficiency across automation systems.

+ Support compliance with customer requirements and internal manufacturing standards related to controls and automation.

+ Champion continuous improvement across automation systems, processes, and engineering practices.

+ Support operational technology cybersecurity initiatives and promote secure industrial networking practices.

+ Ensure appropriate access controls, remote connectivity practices, and disaster recovery considerations for controls systems.

+ Maintain compliance with machine safety and controls-related safety requirements.

+ Provide technical leadership and mentorship to controls engineers and technicians, fostering skill development and best practices.

+ Lead technical reviews and promote standardized engineering approaches across cross-functional teams.

+ Collaborate closely with Operations, Maintenance, Engineering, IT, Quality, and Supply Chain teams to align automation solutions with business needs.

+ Serve as a primary technical contact for vendors, integrators, and customers regarding controls and automation topics.

+ Design, deploy, and support Industrial IoT solutions including data acquisition, edge computing, industrial networking, and enterprise system integration within assigned regions or divisions.

Essential Skills

+ Strong background in Industry 4.0, Industrial IoT, and connected manufacturing technologies.

+ Hands-on experience with PLCs, HMIs, SCADA systems, industrial robotics, and machine automation.

+ Proficiency in designing, programming, commissioning, and troubleshooting PLC, HMI, SCADA, vision, and robotic systems.

+ Strong understanding of industrial communication protocols including Ether Net/IP, Profinet, Profibus, Modbus, and OPC UA.

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Experience with cloud-based IoT platforms, edge devices, MQTT, OPC UA, and enterprise-level system integrations.

+ Knowledge of operational technology cybersecurity concepts including firewalls, VLANs, industrial network segmentation, and disaster recovery.

+ Programming or scripting experience with tools such as Python, SQL, Ignition, Visual Basic, or similar technologies.

+ Proven ability to lead complex automation projects from design through implementation and commissioning.

+ Demonstrated ability to diagnose and resolve complex issues involving controls systems, software, networks, and equipment.

+ Strong…