Senior Controls Engineer

Position Overview: We are seeking a Senior Controls Engineer to lead the design, implementation, and commissioning of industrial automation systems. The role focuses on PLC and HMI development (Rockwell and Beckhoff), machine vision integration, Ignition SCADA projects, AutoCAD Electrical documentation, and production startup. You will drive system integration, apply DevOps practices to control software, troubleshoot complex issues in the field, and mentor junior engineers to deliver reliable, scalable automation solutions on schedule and within budget.

Key Responsibilities: Lead design and development of PLC control systems using Rockwell (Studio 5000/RSLogix) and Beckhoff (TwinCAT) platforms. Develop and maintain HMI/SCADA applications, including Ignition projects and operator interface design. Integrate and configure machine vision systems (e.g., Cognex, Keyence) for inspection, guidance, and part ID applications. Perform systems integration across PLCs, HMIs, vision, motion, safety, and third-party equipment to deliver cohesive solutions. Create and review AutoCAD Electrical schematics, wiring diagrams, and control panel layouts. Implement DevOps practices for control software: version control (Git), build automation, automated testing, and deployment processes. Lead factory acceptance tests (FATs), site acceptance tests (SATs), commissioning, and startup activities; provide on-site troubleshooting and tuning. Produce clear technical documentation, user manuals, and commissioning reports; ensure traceability of changes and configurations. Work with project managers, mechanical and electrical teams, and vendors to define requirements, schedules, and deliverables. Mentor and train junior controls engineers and technicians; promote best practices for coding, testing, and safety compliance.

Qualifications: Bachelors degree in Electrical Engineering, Controls Engineering, Mechatronics, or related field, or equivalent experience.7+ years of hands-on controls engineering experience with a track record of leading automation projects to successful commissioning. Proven expertise in Rockwell (Studio 5000/RSLogix) and Beckhoff (TwinCAT) PLC programming and troubleshooting. Strong HMI/SCADA development skills, including Ignition experience. Experience integrating and configuring vision systems (Cognex, Keyence, or similar) for industrial applications. Proficient with AutoCAD Electrical for creating schematics and control panel documentation. Familiarity with DevOps tools and workflows for control systems: Git, CI/CD pipelines, automated builds/tests, and configuration management. Extensive commissioning/startup experience in manufacturing or process environments; able to work on-site and travel as required. Excellent problem-solving, communication, and leadership skills; able to collaborate with cross-functional teams and manage vendors. Relevant certifications a plus (e.g., Rockwell certifications, Beckhoff training, IPC, automation safety).Valid drivers license and willingness to travel to customer sites for commissioning and support.

Benefits: Vacation/PTO- Medical- Dental- Vision- 401k