Senior Controls Engineer

Seeking an experienced Senior Staff Engineer – Controls to join a leading advanced manufacturing and technology organisation in North Carolina . This is a senior-level technical engineering role responsible for leading controls and automation engineering activities across major manufacturing and capital projects. The position will provide technical leadership across controls architecture, PLC/HMI/SCADA systems, industrial networking, machine automation, commissioning, troubleshooting, and continuous improvement across multiple manufacturing facilities.

Key Responsibilities

• Lead controls engineering activities for major automation, manufacturing technology, and capital projects from initial concept and design through installation, commissioning, startup, and production handover

• Develop, review, and implement industrial controls architectures for automated manufacturing equipment, production systems, and machine-level applications

• Design and program PLC, HMI, SCADA, and control systems supporting complex manufacturing operations

• Provide technical leadership for controls integration across equipment, machines, production lines, and plant systems

• Support and oversee the integration of automation equipment from OEMs, machine builders, system integrators, contractors, and technology suppliers

• Develop and review electrical and controls designs, control narratives, functional specifications, network architectures, I/O documentation, and technical engineering packages

• Support controls system commissioning, factory acceptance testing, site acceptance testing, startup, troubleshooting, and production ramp-up

• Troubleshoot complex controls, automation, electrical, networking, and machine performance issues and develop sustainable corrective solutions

• Support the development and implementation of industrial networking and communication systems including Ethernet/IP, Profinet, OPC UA, and related technologies

• Lead continuous improvement initiatives focused on machine performance, production efficiency, reliability, quality, safety, and overall equipment effectiveness

• Provide technical input into automation standards, controls architecture, equipment specifications, engineering practices, and lifecycle management strategies

• Work closely with Manufacturing Engineering, Electrical Engineering, Operations, Maintenance, IT/OT, Quality, Safety, and external engineering partners

• Mentor and provide technical guidance to engineers and other technical personnel supporting controls and automation projects

• Support multiple manufacturing facilities and provide technical expertise for complex automation and controls challenges

Requirements

• Bachelor's degree or higher in Electrical Engineering, Controls Engineering, Automation Engineering, Mechanical Engineering, or a related technical discipline

• Minimum 10 years of experience in industrial controls, automation, manufacturing engineering, or a closely related engineering environment

• Strong experience with industrial PLC-based control systems and automation technologies

• Hands-on experience with Allen-Bradley / Rockwell Automation PLC platforms

• Experience with HMI and SCADA systems and industrial control system integration

• Strong understanding of industrial networking and controls communication protocols

• Experience supporting automated manufacturing equipment, production lines, machinery, or industrial automation systems

• Ability to lead complex controls engineering projects from concept through commissioning and production handover

• Strong troubleshooting and problem-solving capabilities across controls, electrical, automation, and manufacturing systems

• Strong communication and interpersonal skills with the ability to work effectively across engineering, operations, maintenance, and external technology partners

• Ability to provide technical leadership and mentorship to engineers and technical teams

Preferred Experience

• Experience with Siemens PLCs / TIA Portal in addition to Rockwell Automation

• Experience with Studio 5000, ControlLogix, CompactLogix, FactoryTalk , or similar platforms

• Experience with robotics, machine vision, motion control, servo systems, or automated material handling

• Experience with industrial SCADA platforms such as Ignition, FactoryTalk View, WinCC, or similar

• Experience with industrial communication protocols including EtherNet/IP, Profinet, Modbus TCP, OPC UA, and MQTT

• Experience working with OEMs, machine builders, system integrators, and automation contractors

• Experience with FAT, SAT, commissioning, startup, troubleshooting, and production ramp-up

• Experience developing or implementing controls standards across multiple manufacturing facilities

• Experience with Industry 4.0, MES, IIoT, IT/OT integration, or manufacturing data systems

• Experience with functional machine safety, including GuardLogix, safety PLCs, NFPA 79, ISO 13849, or IEC 62061

• Experience leading large-scale automation or capital projects within a high-volume manufacturing environment

• Professional Engineer (PE) registration or eligibility is advantageous

What's on Offer

• Opportunity to join a leading US advanced manufacturing organisation in a key senior controls engineering position

• Technical leadership across complex automation, manufacturing technology, and capital projects

• Exposure to multiple manufacturing facilities and advanced automated production systems

• Opportunity to influence controls architecture, automation standards, manufacturing technology, and equipment reliability

• Collaborative environment working closely with Engineering, Manufacturing, Operations, Maintenance, IT/OT, and external technology partners

• Opportunity to mentor engineers and provide technical leadership across major automation initiatives

• Long-term career development within a major US industrial and manufacturing organisation

• Opportunity to influence manufacturing performance, automation capability, reliability, and continuous improvement

Compensation & Benefits

• Competitive base salary

• Annual performance bonus

• Comprehensive medical, dental, and vision coverage

• 401(k) retirement plan with company contribution and match

• Life insurance and disability coverage

• Paid time off and company holidays

• Employee assistance and wellness programs

• Ongoing technical training and professional development opportunities