Senior Controls Engineer In Automation

Job Title: Senior Controls Engineer in Automation Job Description The Senior Controls Engineer is responsible for the planning, design, programming, and implementation of PLC, HMI, and PC-based control systems for industrial automation projects. This role leads the development of control solutions that may include PLC programming, PC programming (.NET), HMI design, robot programming, machine vision, and industrial communication networks. The Senior Controls Engineer interprets project scope and technical requirements, balances client expectations with budget and schedule constraints, and ensures successful technical execution from concept through commissioning and on-site startup. Responsibilities Plan, design, program, and implement PLC, HMI, and PC-based control systems for large automation machinery projects. Interpret customer-supplied control descriptions, conduct interviews with clients and owners, and analyze mechanical system requirements to create functional software designs. Develop and program control systems for automated equipment, including PLCs, AC and servo motion control, robotics, machine vision, bar-code and RFID applications, and related automation technologies. Create highly structured, well-documented, and reliable PLC and PC programs that align with established company standards. Design intuitive, easy-to-navigate, and visually appealing HMI interfaces and SCADA screens that support efficient operation and troubleshooting. Program PLC systems from beginning to end, including configuration, logic development, testing, and deployment for platforms such as Rockwell, Siemens, and Allen-Bradley. Program and integrate industrial robots, including 6-axis robots and platforms such as Fanuc, UR, and ABB, into automated systems. Develop software and test plans to support thorough, systematic in-house testing prior to on-site commissioning. Perform comprehensive testing of system software to verify functionality, reliability, and safety before exposing systems to the client. Interface with outside vendors for the selection of components and coordination of manufacturing and assembly activities. Commission machines to meet customer quality, performance, and cycle time requirements, including on-site testing and startup support. Ensure that automation projects are delivered on time, within scope, and within budget while maintaining high technical quality. Create and maintain comprehensive project documentation, including design specifications, test plans, operating procedures, and change records. Collaborate effectively with other project team members to share programming responsibilities and ensure cohesive system integration. Apply strong mechanical and electrical aptitude to troubleshoot and optimize control systems and automated equipment. Demonstrate flexibility and enthusiasm in a role where daily tasks and challenges frequently vary. Provide project management and technical leadership on controls projects, coordinating tasks, timelines, and resources to achieve project goals. Maintain effective communication with cross-functional teams and clients to clarify requirements, report progress, and resolve issues. Essential Skills 5+ years of experience in the planning, design, programming, and implementation of PLC, HMI, and PC-based control systems. 5+ years of experience working on large automation machinery projects. 5+ years of experience with data logging and programming HMI interfaces and databases. 4+ years of experience with machine vision systems. 5+ years of experience in project management or technical leadership within automation or controls engineering projects. 5+ years of experience demonstrating excellent interpersonal skills and the ability to work effectively in a cross-functional team environment. Highly competent to expert-level PLC and PC programming skills. Proficiency in PLC programming, including platforms such as Rockwell and Allen-Bradley. Experience with Siemens PLCs and related software tools. Strong HMI programming experience, including the design of intuitive and user-friendly interfaces. Experience with SCADA systems and integration with plant-floor equipment. Hands-on experience with AC and servo motion control programming. Experience with industrial robots, including 6-axis robots and platforms such as Fanuc, UR, and ABB. Experience with robotics integration, machine vision, bar-code, and RFID applications in automated systems. Strong mechanical and electrical aptitude relevant to automated equipment and industrial control systems.