Job Description

Job Title: Senior Controls Engineer Automation & Manufacturing Systems

Location: Onsite / Hybrid (Travel as required)

Employment Type: Full-Time / Contract

About the Role

In this role, you will be responsible for the design, implementation, and scaling of automated and semi-automated control systems using advanced engineering principles and cutting-edge technologies. You will develop PLC code that integrates with subsystems such as conveyors, robotics, MES, machine vision, and third-party equipment to drive high-quality, efficient manufacturing operations.

You'll also lead new technology development, upgrade legacy control systems, and provide technical mentorship to suppliers and internal engineering teams - all while ensuring compliance with ANSI/RIA15.06/OSHA safety standards.

Key Responsibilities

• Design and implement factory-level and machine-level controls standards and specifications.
• Develop and debug PLC ladder logic and IPC software (Rockwell Logix, GE RXi) with well-documented, maintainable, and reusable code.
• Integrate PLC systems with MES, robotics, conveyors, and vision systems.
• Design control-reliable safety systems for safeguarding high-volume manufacturing equipment.
• Create intuitive HMI screens that simplify complex processes while providing rich diagnostic feedback.
• Collaborate with IT to connect manufacturing assets to the enterprise network.
• Research and develop innovative control system technologies to solve complex manufacturing challenges.
• Write and manage RFQs/RFPs and lead cross-functional design reviews with equipment suppliers.
• Support equipment qualification, testing, and build activities on-site and at supplier facilities.
• Stay up to date with new technologies and industry trends to enhance automation processes.
• Provide technical guidance and mentorship to internal and external engineering teams.

Minimum Qualifications

• Bachelor's degree in Engineering, Computer Science, or related discipline.
• 7+ years of experience with Rockwell Logix platforms.
• Strong background in manufacturing automation (not logistics).
• Proven experience in controls programming, hardware design, and OT infrastructure.
• Proficiency with Industrial Communication Protocols (EtherNet/IP, Modbus, etc.).
• Experience designing and validating machine safety circuits and safety PLCs.
• Experience in automated manufacturing equipment qualification, DOE, and failure analysis.

Preferred Qualifications

• Expert-level experience in high-volume automated process equipment using Rockwell Logix and GE RXi.
• Familiarity with SCADA platforms, Historians, OPC Servers, and Industry 4.0 implementations.
• Experience with IoT integration, SQL, and scripting languages (Python/Java preferred).
• Exposure to Fanuc robotics, SAP/ERP systems, and machine vision.
• Excellent problem-solving, time management, and analytical skills.
• Strong leadership, collaboration, and communication abilities.
• Ability to travel for supplier qualifications and on-site support (typically short trips).

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