Senior Controls Engineer

Job title : Senior Controls Engineer

Reports to : Controls Engineering Manager

Supervisory responsibilities : No

Summary/objective : Specialty Tooling Systems is seeking a Senior Controls Engineer to lead the design, development, and implementation of advanced automation systems and custom machinery. This role is responsible for driving technical excellence across projects, from concept through commissioning, while mentoring team members and serving as a key technical resource for both internal teams and customers.

The ideal candidate brings deep expertise in controls systems and thrives in a fast-paced, highly collaborative environment focused on delivering high-precision, state-of-the-art equipment.

Essential functions :

• Lead controls engineering efforts across the full project lifecycle: concept development, design, build, validation, customer acceptance, and onsite commissioning
• Serve as a technical lead on projects, guiding architecture decisions, standards, and best practices
• Define controls architecture and make key technical decisions for assigned projects
• Lead the design and development of complex control systems including PLCs, motion control, robotics, vision systems, and HMI/SCADA platforms
• Program, integrate, and troubleshoot systems involving Rockwell Automation platforms, robotics, and advanced automation technologies
• Collaborate cross-functionally with mechanical engineering, project management, and manufacturing teams to deliver integrated solutions
• Serve as primary technical point of contact for customers on controls-related topics
• Lead troubleshooting and root cause analysis for system performance, reliability, and quality issues
• Identify project risks early and drive mitigation strategies in collaboration with project managers
• Contribute to project estimating, concept development, and system architecture definition
• Drive continuous improvement initiatives related to controls standards, documentation, and development processes
• Establish and enforce controls standards and best practices
• Mentor and develop junior engineers through technical guidance, code reviews, and best practice sharing
• Stay current with emerging technologies and industry best practices; apply knowledge to improve solutions and processes

Required competency, education, and experience :

• 7+ years of controls engineering experience in automation or custom machinery
• Demonstrated ability to lead technical aspects of projects independently
• Strong experience with:
  • Rockwell Automation (Studio 5000 & FactoryTalk View)
  • Industrial robotics (FANUC preferred)
  • Automated assembly systems and machine integration
• Proven expertise in PLC programming, motion control, and system integration
• Strong troubleshooting and problem-solving skills in complex automated systems
• Ability to manage multiple projects and priorities in a dynamic environment
• Excellent communication and interpersonal skills, including customer-facing experience
• High attention to detail and commitment to quality
• Ability to maintain confidentiality on sensitive projects
• Proficient in 2D electrical CAD (AutoCAD Electrical preferred)
• Valid driver’s license; ability to travel as required
• Legally authorized to work in the United States without sponsorship

Preferred Qualifications :

• Bachelor’s degree in Electrical Engineering or related field (or equivalent industry experience)
• Additional/Advanced experience with:
  • Rockwell platforms (GuardLogix, ControlLogix, FactoryTalk View)
  • Robotics: FANUC, ABB, MOTOMAN
  • Robotic Simulation: Roboguide, Robot Studio, MotoSim, and Process Simulate
• Experience with additional platforms (Siemens, Omron)
• Other Supporting experience with:
  • Artificial Intelligence tools (ChatGPT, Claude, local LLMs)
  • Custom (Python, VBA)
• Experience developing controls standards or leading continuous improvement initiatives
• Prior experience mentoring or providing technical leadership to engineering teams

Work environment : Office setting within a manufacturing environment, with regular interaction on the production floor.

Physical demands :

• Ability to sit for extended periods
• Ability to view detailed work at close range
• Manual dexterity to work with small components
• Ability to lift 20 pounds

Position type and expected hours of work : Full time

Travel : 0-30% potential travel associated with role as needed.

• Travel may require:
  • Domestic and international travel
  • Air travel
  • Overnight stays (typically up to 2-week intervals for large projects)

Compensation/Benefits:

• Competitive salary
• Health, dental, and vision insurance
• Short-term and long-term disability
• Company-paid and voluntary life insurance
• 401(k) with company match
• Education reimbursement
• Paid vacation and holidays
• Flexible spending accounts

Other duties : This job description is not intended to be all-inclusive. Responsibilities may evolve based on business needs.

STS is an Equal Opportunity Employer. STS does not discriminate on the basis of race, religion, color, sex, gender identity, sexual orientation, age, non-disqualifying physical or mental disability, national origin, veteran status, or any other basis covered by appropriate law. All employment is decided on the basis of qualifications, merit, and business need