Senior Controls Engineer

Responsibilities

The Senior Controls Engineer owns the facility's automation control systems to maximize reliability, safety, and Overall Equipment Effectiveness (OEE). This role balances advanced hands-on troubleshooting of PLC, HMI, SCADA, and robotic systems with end-to-end capital project management. The incumbent collaborates across all business functions and external vendors to deliver engineering solutions with minimal production downtime.

Core Responsibilities

Automation Ownership: Serve as the sole authority for plant control networks (Level 0–2), PLC/SCADA programming, and process control IT policies.

Troubleshooting & Support

Diagnose complex system faults, perform root cause analyses, and implement rapid repair solutions to maximize OEE.

System Integrity

Maintain master backups and rigorous change-management records for all automation programs and hardware configurations.

Capital Projects

Lead engineering projects from inception to completion, managing scopes, RFAs, technical specs, vendor quotes, timelines, and budgets. \ Continuous Improvement: Evaluate new technologies and implement process upgrades to eliminate waste, improve safety, and reduce downtime.

Safety & Compliance

Enforce company, state, and federal EHS policies, including authorizing emergency equipment shutdowns when necessary.

Mentorship

Train and mentor junior engineers, maintenance supervisors, and craft technicians on automated systems. Performing other duties as assigned.

Qualifications

Basic Qualifications

A Bachelor’s degree in Electrical Engineering or Electrical Engineering Technology. Minimum five (5) years of experience in programming and maintaining PLCs, HMIs, and Databases. Candidate must have a strong working knowledge of control and automation programs, including robotics and automation in industrial manufacturing. This position is subject to the International Traffic in Arms Regulations (ITAR), which requires U.S. person status.

ITAR defines U.S. person as an U.S. Citizen, U.S. Permanent Resident (i.e. ‘Green Card Holder’), Political Asylee, or Refugee Preferred Qualifications: Experience with Allen Bradley PLCs and HMIs. Experience with ABB Robots, Robot Studio and vision systems a plus. Experience with Ignition, SCADA Familiarity with programming VB.Net, Python, Java, Java Script, Microsoft SQL Server, Windows Administration, and Network Management.

Device integration experience via serial, TCP/IP, OPC-UA and proprietary protocols. Experience working within a heavy manufacturing environment. The ability to effectively communicate (verbally and written) and delegate while maintaining forward motion on key deliverables. A high degree of interpersonal skills to motivate and influence others, including those not under their direct supervision. Demonstrated abilities of problem solving, systems thinking, project management, and team building.

Working Conditions This position involves moderate exposure to risk of accident and requires following basic safety precautions. Work is normally performed in an interior work environment, while regularly accessing plant equipment for assessment. While not exposed to hazardous materials, this position requires wearing full PPE to protect from mobile equipment and hot materials when on the shop floor. This position requires moderate physical activity, such as all motions necessary to inspect production equipment in and out of confined spaces.

This position also requires a willingness to maintain a flexible work schedule and travel (typically 10% or less) both domestically and internationally, as requested.