Senior Controls Engineer

Location: Grand Rapids, Michigan, USA

Job Type: Full-Time

Reports To: Controls Engineering Manager

Travel: 0-30%, as required

Position Summary

We are seeking an experienced Senior Controls Engineer to lead the design, development, programming, integration, and commissioning of advanced automation systems and custom machinery.

The ideal candidate will bring strong expertise in PLC programming, motion control, industrial robotics, and machine integration. This role involves technical leadership throughout the project lifecycle, customer interaction, cross-functional collaboration, and mentoring junior engineers.

Key Responsibilities

Lead controls engineering projects from concept development through design, build, validation, customer acceptance, and onsite commissioning.

Define controls architecture and make key technical decisions for assigned projects.

Design, develop, program, and integrate PLCs, motion control systems, robotics, machine vision, and HMI/SCADA platforms.

Program and troubleshoot Rockwell Automation platforms, including Studio 5000 and FactoryTalk View.

Integrate and troubleshoot industrial robotics systems, preferably FANUC.

Collaborate with mechanical engineering, project management, and manufacturing teams to deliver integrated automation solutions.

Serve as the primary technical point of contact for customers on controls-related matters.

Lead troubleshooting and root cause analysis to resolve system performance, reliability, and quality issues.

Identify project risks and develop mitigation strategies in collaboration with project managers.

Contribute to project estimating, concept development, and system architecture definition.

Establish and maintain controls standards, documentation, and engineering best practices.

Drive continuous improvement initiatives to improve engineering quality and efficiency.

Mentor junior engineers through technical guidance, code reviews, and knowledge sharing.

Stay current with emerging automation technologies and industry best practices.

Required Qualifications 7+ years of controls engineering experience in industrial automation or custom machinery.

Demonstrated ability to independently lead technical aspects of engineering projects.

Strong experience with Rockwell Automation platforms, including Studio 5000 and FactoryTalk View.

Experience with industrial robotics, preferably FANUC.

Experience with automated assembly systems and machine integration.

Proven expertise in PLC programming, motion control, and system integration.

Strong troubleshooting, analytical, and problem-solving skills.

Proficiency in 2D electrical CAD software, preferably AutoCAD Electrical.

Ability to manage multiple projects and priorities in a dynamic environment.

Excellent Communication And Interpersonal Skills, Including Customer-facing Experience. Strong attention to detail and commitment to quality.

Ability to maintain confidentiality on sensitive projects.

Valid driver's license and willingness to travel as required.

Legally authorized to work in the United States without employer sponsorship.

Preferred Qualifications Bachelor's degree in Electrical Engineering or a related field, or equivalent industry experience.

Advanced experience with Rockwell Automation platforms, including GuardLogix, ControlLogix, and FactoryTalk View.

Experience with FANUC, ABB, or Yaskawa MOTOMAN robotics.

Familiarity with robotic simulation software such as ROBOGUIDE, RobotStudio, MotoSim, or Process Simulate.

Experience With Additional Automation Platforms, Including Siemens Or Omron. Experience using AI tools such as ChatGPT, Claude, or locally hosted large language models.

Programming experience with Python, VBA, or similar tools.

Experience developing controls standards and leading continuous improvement initiatives.

Previous experience mentoring engineers or providing technical leadership to engineering teams.

Work Environment and Physical Requirements

Office-based work within a manufacturing environment, with regular interaction on the production floor.

Ability to sit for extended periods.

Ability to view detailed work at close range.

Manual dexterity to work with small components.

Ability to lift up to 20 pounds.

Travel Requirements

The position may require up to 30% travel, including domestic and international travel, air travel, and overnight stays. Longer project assignments may require stays of up to two weeks.

Compensation And Benefits Competitive salary.

Medical, dental, and vision insurance.

Short-term and long-term disability coverage.

Company-paid and voluntary life insurance.

401(k) retirement plan with company match.

Education reimbursement.

Paid vacation and holidays.

Flexible spending accounts.

Equal Employment Opportunity

The employer is an Equal Opportunity Employer. Employment decisions are based on qualifications, merit, and business needs, without discrimination on any basis protected by applicable law.