Sr. Controls Engineer
Core
Lead automation acceptance, commissioning, and live support for a massive manufacturing facility expansion, focusing on PLC programming, robotics integration, and system validation.
Role type
Senior Controls Engineer (FAT/CSV)
Builds
New and existing automation equipment, robotics cells, vision systems, and material handling systems for defense, aerospace, and automotive industries.
Domain
Industrial Automation / Manufacturing
Deliverable
production ML models | product features | dashboards & analysis | research | client delivery | infrastructure | physical/clinical work -> infrastructure (PLC code, HMI screens, safety circuits, network configurations, FAT/SAT protocols, commissioning records)
Required skills
PLC programming (Siemens, Allen Bradley/Rockwell), HMI development, robotics integration, motion control (servos, VFDs), industrial networking (Ethernet/IP, Profinet, EtherCAT, OPCUA, Modbus), technical writing, FAT/SAT campaign management, change control, safety circuit design, SCADA configuration.
Preferred skills
Robotics & Vision Systems experience (Fanuc, Kuka, ABB, Cognex, Keyence), SCADA application development (Ignition, FactoryTalk, Wonderware), AGV integration, Python/C++ programming, regulated industry experience (Defense, Aerospace, Automotive), GAMP 5 / computer system validation exposure.
Technologies
Siemens PLCs, Allen Bradley/Rockwell PLCs, HMIs, Fanuc, Kuka, ABB robots, Cognex, Keyence vision systems, Ignition, FactoryTalk, Wonderware, Ethernet/IP, Profinet, EtherCAT, OPCUA, Modbus, MES, SCADA.
Responsibilities
Lead hands-on programming, debugging, and commissioning of PLCs and HMIs; develop and maintain PLC code structures, safety circuits, and networking configurations; execute scaling-equipment design-review campaigns; review vendor electrical schematics and controls architectures; author and execute FAT/SAT protocols and manage punch lists; integrate robotics, vision systems, AGVs, and motion control systems; configure communications between PLCs/HMIs and higher-level systems (MES/SCADA); serve as senior escalation point for complex automation issues.
Seniority
Senior, hands-on IC
