Sr. Controls Engineer

Senior Controls Engineer

Overview
We are looking for a highly skilled Senior Controls Engineer to lead the design, installation, integration, and commissioning of complex industrial automation systems. This role demands a practical, hands-on approach that combines PLC programming, controls expertise, and field leadership. The ideal candidate will be comfortable working closely with electricians, millwrights, installers, and subcontractors to successfully bring automated systems from conception to operational startup. If you thrive in a role that involves both programming and physical implementation, this opportunity is tailored for you.

Responsibilities

• Develop, program, troubleshoot, and commission PLC-based industrial control systems.
• Support controls projects from initial design and programming through installation, startup, and final commissioning.
• Collaborate directly with electricians, millwrights, technicians, and installation crews in the field.
• Assist with equipment installation, hardware mounting, cable routing, instrumentation, and pneumatic systems as needed.
• Troubleshoot electrical, controls, communication, and mechanical issues during startup and commissioning phases.
• Develop and maintain industrial communication networks.
• Support the integration of plant-floor equipment with control systems, manufacturing systems, and databases.
• Provide remote technical support to current and potential customers.
• Create comprehensive controls documentation, troubleshooting procedures, and technical records.
• Identify and incorporate emerging automation technologies into control system solutions.

Technologies & Systems Candidates May Work With:
PLC and HMI programming, industrial communication networks, AS-Interface/AS-i networks, SCADA and visualization platforms, database and system integration, Ignition, machine vision, industrial cameras, pneumatic control, conveyor and material handling systems, track switches, vertical lifts, industrial washers and ovens, automated finishing and coating equipment, robotic and reciprocating automation.

Field & Leadership Responsibilities

• Lead technical conversations and coordinate activities on-site, managing subcontractors and field teams.
• Make sound engineering and troubleshooting decisions during installation and startup.
• Coordinate controls, electrical, mechanical, and installation teams for seamless project execution.
• Provide technical guidance to electricians, technicians, and installers.
• Communicate effectively with customers regarding project progress and technical issues.
• Uphold safety, quality, documentation, and professional standards throughout project execution.
• Manage smaller projects independently at customer sites, demonstrating ownership and accountability.

Ideal Candidate
The successful candidate is a proactive, hands-on engineer who takes ownership of field projects. Essential qualifications include:

• Extensive PLC programming and industrial controls experience.
• Proven experience commissioning automated industrial equipment.
• Strong electrical troubleshooting skills.
• Mechanical aptitude and willingness to work hands-on with field personnel.
• Familiarity with industrial networking and communication protocols.
• Ability to troubleshoot systems involving controls, electrical, pneumatic, and mechanical components.
• Experience coordinating field installation teams and subcontractors.
• Excellent customer-facing communication skills.
• Strong technical documentation practices.
• Ability to work independently with minimal supervision.
• Strong problem-solving and technical decision-making abilities.
• Interest in emerging technologies, such as machine vision, advanced sensors, cameras, and connected manufacturing systems.

Experience with conveyor systems, material handling, process equipment, automated manufacturing, finishing systems, robotics, or other industrial automation environments is highly desirable.

Travel Requirements
Approximately 50% travel annually is anticipated. During busy project periods, travel may follow rotations of approximately three weeks on-site followed by one week at home. Candidates should be comfortable traveling to industrial customer sites and working directly within active installation and commissioning environments.

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