Senior Control Engineer

Summary

Design, program, troubleshoot, and support automated manufacturing systems. This role is responsible for PLC programming, electrical controls design, equipment commissioning, process improvements, and customer support for automation projects in manufacturing environments.

Key Responsibilities

• Design and develop automated control systems and machine controls.
• Create and modify PLC programs, HMI screens, ladder logic, electrical schematics, panel layouts, and wiring diagrams.
• Design control systems that meet safety standards and customer requirements.
• Use AutoCAD to create and maintain electrical drawings and documentation.
• Lead internal and customer design reviews.
• Develop project bills of materials, timelines, and technical documentation.
• Evaluate and implement new automation technologies and equipment upgrades.
• Troubleshoot PLCs, controls, machine inputs/outputs, and automation equipment.
• Analyze manufacturing processes and implement continuous improvement solutions.
• Support equipment startup, commissioning, validation, and customer acceptance testing.
• Provide remote and on-site technical support to customers.
• Maintain controls spare parts inventory and coordinate replacement parts as needed.
• Document designs, inspections, repairs, and project activities.
• Travel up to 35% for installations, commissioning, and customer support.
• Work overtime or weekends as required to support project schedules.

Qualifications

• 5+ years of PLC programming experience in an industrial or manufacturing environment.
• Strong experience with Allen-Bradley ControlLogix and CompactLogix PLC platforms.
• Experience with Siemens PLCs, Automation Direct, and HMI systems is a plus.
• Proficiency with AutoCAD, electrical schematics, panel layouts, and ladder logic documentation.
• Strong understanding of industrial controls, including sensors, proximity switches, photo-eyes, solenoid valves, VFDs, servo drives, and PLC I/O.
• Ability to read and interpret electrical drawings, machine prints, schematics, and ladder logic.
• Knowledge of electrical, mechanical, pneumatic, and hydraulic systems.
• Strong troubleshooting, problem-solving, and analytical skills.
• Excellent verbal, written, and interpersonal communication skills.
• Ability to work effectively in a team environment and interact with customers.

Preferred Education & Experience

• Bachelor's degree in Electrical Engineering, Computer Engineering, Computer Programming, or a related field preferred.
• 3-5+ years of experience supporting automated equipment, high-speed machinery, or manufacturing systems.
• Experience commissioning new equipment, motion control systems, and providing field support.
• Expert knowledge of ladder logic architecture and industrial control systems.
• Knowledge of motion control, VFDs, HMIs, Servo Systems, PID controls, and automated machine integration strongly preferred.
• Experience supporting equipment startups, upgrades, and repairs in a manufacturing environment.
• Familiarity with OSHA, ANSI, and industrial safety standards.