Senior Controls Engineer

Position OverviewThe Senior Controls Engineer is responsible for designing, programming, and optimizing automated production systems within a high-volume manufacturing environment. This role plays a critical part in improving equipment performance, increasing throughput, reducing downtime, and supporting the commissioning of complex, custom-built machinery. The position requires strong PLC and robotics expertise, advanced troubleshooting capability, and the ability to thrive in a fast-paced production setting.

Key ResponsibilitiesDevelops PLC programs in ladder logic and structured text for production equipment, automated transfer systems, robotics, and quality inspection devices.

Modifies and optimizes existing PLC, motion control, and servo logic to improve cycle time, uptime, and overall equipment performance.

Integrates sensors, thermal devices, machine vision systems, actuators, and safety components, including configuration of I/O and industrial communication protocols such as Ethernet/IP, Modbus, and Profinet.

Leads debugging, diagnostics, and root-cause analysis for PLCs, HMIs, robotics, motion systems, and safety systems during installation, startup, and commissioning.

Supports equipment start-up, factory and site acceptance testing, final commissioning, and integration into manufacturing workflows.

Analyzes automated processes to identify bottlenecks, inefficiencies, and opportunities for throughput, quality, and reliability improvements.

Creates and maintains electrical schematics, functional design specifications, PLC and HMI documentation, standards, and change records.

Provides technical oversight to internal teams and suppliers while training maintenance and production personnel on new systems and upgrades.

QualificationsBachelors degree in electrical engineering, controls engineering, automation, mechatronics, software engineering, or a related discipline.

Extensive hands-on PLC programming experience using ladder logic and structured text.

Experience designing and implementing new production processes and automation systems.

Demonstrated ability to develop PLC programs from the ground up for new manufacturing equipment.

Experience integrating sensors, motion systems, machine vision, and automation hardware.

Strong troubleshooting skills across electrical, PLC, robotic, and automation systems.

Experience with Allen-Bradley/Rockwell Automation and or Siemens PLC platforms.

Ability to read and interpret electrical schematics using EPLAN or AutoCAD.Working knowledge of SCADA, MES, data acquisition systems, and industrial networking.

Experience commissioning custom-built equipment or greenfield production lines is preferred.

Experience with robotics platforms such as Fanuc, Kuka, ABB, or Kawasaki is strongly preferred.

Compensation and BenefitsCompetitive salary range of $120,000 - $135,000 plus bonus eligibilityMedical, Dental, and Vision insurance401(k) programGenerous Paid Time Off planPaid maternity and paternity leaveCommuter benefitsAdditional supplemental benefits