Title:

Senior Controls EngineerTitle:

Birmingham, ALSalary:

$140,000 - $150,000Founded in 1999, this privately-held industrial automation and systems integration organization employs approximately 30-50 employees, with the majority of its engineering, project management, controls, panel fabrication, and support teams operating from its Birmingham, Alabama headquarters. We specializes in automation integration, robotics, motion control, machine vision, PLC/HMI programming, control panel design and fabrication, conveyance systems, and manufacturing process optimization for industrial clients throughout the United States. Our Birmingham operation serves as the primary engineering and execution hub, supporting the design, programming, commissioning, startup, and lifecycle support of custom automation solutions. Industries served include automotive, metals, manufacturing, consumer products, food and beverage, packaging, engineered products, and other industrial production environments.

Position OverviewWe are seeking a Senior Controls Engineer to lead the design, implementation, and commissioning of industrial control systems for process and manufacturing applications. The successful candidate will be responsible for architecture, programming, integration, and validation of

PLC/HMI/SCADA

systems, motion control and drives, and instrumentation. This role serves as a technical lead and mentor, driving best practices for control system development, functional safety, and system reliability while coordinating with multidisciplinary engineering, project managers, vendors, and clients.

Key ResponsibilitiesLead design, development and deployment of PLC, HMI and SCADA control systems for new and retrofit projects.

Program and maintain controllers across multiple platforms (Allen-Bradley/Rockwell, Siemens, Schneider, Mitsubishi, Honeywell) using

IEC 61131-3

languages: Ladder Logic, Structured Text, Function Block Diagram and other vendor-specific tools.

Architect and implement control strategies, control loops and PID tuning, and apply control theory and loop design best practices.

Design and commission VFDs, motor control, servo and motion control systems, including tuning and performance validation.

Specify and interpret P&IDs, instrumentation diagrams and I/O lists; select sensors and field devices including thermocouples, transmitters and actuators.

Develop industrial network architectures and configure communications using Profibus, Profinet, Ethernet/IP, OPC/UA and MQTT; ensure secure and reliable data exchange with SCADA and enterprise systems.

Prepare electrical panel designs, wiring schematics and AutoCAD Electrical drawings; oversee panel fabrication and wiring quality.

Plan and execute FAT, SAT and on-site commissioning activities; perform system integration, start-up support and detailed troubleshooting.

Implement and validate functional safety requirements (SIL assessments, safety lifecycle) in accordance with

IEC 61508/61511

where applicable.

Create and maintain clear documentation: functional specifications, control narratives, test plans, commissioning reports and SOPs.

Use Matlab/Simulink and controls modeling tools for simulation, algorithm development and performance verification.

Mentor and coach junior controls engineers and technicians; provide technical leadership and review code, design and test results.

Collaborate with project managers, mechanical and electrical teams, vendors and clients to deliver projects on schedule and within budget.

Drive continuous improvement by establishing standards, reusable libraries, code templates and engineering best practices.

QualificationsBachelors degree in Electrical Engineering, Control Systems, Mechatronics or a related engineering discipline (Masters preferred).7+ years of hands-on experience in industrial controls engineering, programming and commissioning. Senior-level experience across multiple industries preferred.

Proven programming and implementation experience with PLCs and HMIs; familiarity with Allen-Bradley/Rockwell, Siemens, Schneider, Mitsubishi and Honeywell platforms.

Strong knowledge of

IEC 61131-3

languages (Ladder, Structured Text, Function Block Diagram) and control design fundamentals including PID tuning and control theory.

Experience with industrial networks and protocols: Profibus, Profinet, Ethernet/IP, OPC/UA and MQTT.Experience with VFDs, motor control, servo/motion control systems and associated drives.

Practical experience with instrumentation, thermocouples, P&IDs, electrical panel design and AutoCAD Electrical.

Experience planning and executing FAT/SAT and site commissioning, system integration and complex troubleshooting.

Working knowledge of functional safety standards (SIL, IEC 61508/61511) and experience implementing safety-related systems.

Familiarity with SCADA platforms and tools (Ignition preferred), OPC connectivity and HMI design best practices.

Experience with Matlab/Simulink or equivalent simulation tools for controls modeling and verification.

Strong communication, project leadership and documentation skills; proven ability to work with cross-functional teams and mentor junior staff.

Professional certifications a plus: Rockwell or Siemens training, ISA/functional safety certification, PMP or equivalent project management credential.

BenefitsComprehensive medical, dental, and vision insurance coverage401(k) retirement plan with company matchCompany-paid life insurance and short-term/long-term disability coveragePaid vacation, sick leave, and company holidaysProfessional development support, including technical training, manufacturer certifications, and continuing education opportunitiesExposure to cutting-edge automation technologies including robotics, machine vision, motion control, and advanced manufacturing systemsCompany-provided laptop, software tools, and other resources necessary for project executionTravel opportunities to customer facilities across a diverse range of manufacturing industriesCollaborative, engineering-driven culture focused on innovation, continuous improvement, and customer successLong-term career growth within a respected automation systems integration organization