Senior Controls Engineer

Job Summary

Insight Global is seeking a Senior Controls Engineer to join their team in Aiken, SC. This role supports a high-volume automotive manufacturing facility that produces molded carpet, foam, and insulation components used in vehicle interiors. The engineer will primarily support the molding and assembly operations, working with PLC-controlled automation systems that include robotics, vision inspection systems, VFDs, hydraulics, and manufacturing execution systems (MES). This position is approximately 40% production support and 60% project work, requiring someone who can quickly troubleshoot line-down situations while also driving automation improvements, controls modifications, capital projects, and equipment upgrades. The engineer will work closely with Maintenance, Production, Engineering, and another Senior Controls Engineer to improve uptime, process reliability, machine performance, and plant automation initiatives across a 24/7 manufacturing environment.

Must Have Skillsets

• 2+ years of hands-on controls, automation, manufacturing engineering, or PLC programming experience in a production environment
• Experience troubleshooting and modifying PLC programs in a manufacturing setting.
• Experience supporting automated equipment, production lines, machinery, or industrial controls systems.
• Ability to troubleshoot production issues involving PLCs, VFDs, motors, sensors, hydraulics, and machine controls.
• Ability to troubleshoot basic vision system issues and understand how vision systems interact with PLCs, robotics, and production equipment.

Plusses (Skillsets)

• Experience with Siemens or Allen-Bradley / Rockwell Automation PLCs.
• Experience with Keyence vision systems or other machine vision platforms.
• Experience with robotics, robotic integration, or automated assembly systems.
• Experience with MES, manufacturing data collection, industrial networking, or production reporting systems.
• Automotive manufacturing experience.
• Electrical Engineering, Controls Engineering, Mechatronics, or related degree (not required).