Controls Engineer

Controls Engineer Job Description

This role focuses on developing, commissioning, and deploying advanced automation systems used in the assembly of electronic devices. The Controls Engineer will primarily work with PC-based control systems programmed in C#, while also supporting PLCs, motion control, and integrated machine hardware. This is a hands‑on position that spans the full machine lifecycle, from software development and integration through installation, commissioning, and production support.

The role includes an initial training and knowledge transfer period overseas, followed by leading installation and start‑up activities in the United States.

• Develop, maintain, and troubleshoot PC‑based control software using C# (.NET) for custom automation equipment.
• Integrate and commission automation systems including PLCs, motion controllers, servo drives, and PC‑based control platforms.
• Modify, test, and debug PLC programs for platforms such as Siemens, Allen‑Bray­ley, and Omron as part of overall system integration.
• Configure and tune motion control systems, including servo drives, axes, and motion profiles, to meet performance and reliability requirements.
• Support machine bring‑up activities, including initial power‑up, debugging, and optimization of new automation equipment.
• Lead commissioning efforts and support production ramp‑up activities to ensure stable and efficient operation of automated systems.
• Perform system validation, including I/O checks, functional testing, and failure mode or negative scenario testing to verify system robustness.
• Deploy software builds to machines using proper version control, backup, and rollback procedures to maintain software integrity.
• Troubleshoot and resolve issues across software, electrical, and motion control components, working systematically to identify root causes.
• Integrate and calibrate sensors, vision systems, and industrial transducers to ensure accurate and reliable data acquisition.
• Support the development and maintenance of HMI functionality, including multilingual or dual‑language interfaces for operators.
• Collaborate closely with mechanical, electrical, and manufacturing teams during system integration to ensure cohesive system performance.
• Document commissioning activities, test results, configuration changes, and maintain detailed software version history for traceability.
• Participate in onsite training and knowledge transfer activities at the equipment development location to prepare for installation and start‑up in the United States.
• Serve as the primary controls engineer during installation and start‑up of the equipment in the U.S., applying knowledge gained during the training period.

• Experience with PC‑based automation programming in C# (.NET).
• Proficiency in C# programming for industrial control and automation applications.
• Hands‑on experience commissioning and supporting industrial automation equipment.
• Experience with PLC programming, including development, modification, testing, and debugging.
• Ability to work with PLC platforms such as Siemens, Allen‑Bray­ley, and Omron.
• Experience with motion control systems, including configuring and tuning servo drives, axes, and motion profiles.
• Strong skills in troubleshooting and resolving issues across software, electrical, and motion control components.
• Experience with PC‑based automation systems and integrated machine hardware.
• Ability to perform system validation, including I/O checks, functional testing, and failure mode or negative scenario testing.
• Familiarity with integrating and commissioning automation systems that include PLCs, motion controllers, servo drives, and PC‑based platforms.

The role begins with a four‑week travel period in India, in an engineering and manufacturing environment where the Controls Engineer will train and learn the technology used in the automation equipment. During this period, the schedule is six days per week with 10‑hour workdays, providing significant overtime opportunities. Following the training phase, the position transitions to a facility in Houston, Texas, where the engineer will support installation, start‑up, and…