Job Title: Experienced Controls Engineer
Job Description
The Experienced Controls Engineer is responsible for the planning, design, programming, and implementation of PLC, HMI, and PC-based control systems for industrial automation projects. This role covers the full lifecycle of systems integration, including system design, PLC and PC programming (.NET), HMI development, robot programming, machine vision, industrial communication network implementation, in-house testing, and on-site commissioning. The Experienced Controls Engineer understands each project’s scope, goals, and technical requirements, and consistently balances client expectations, budget, schedule, and technical execution to achieve successful project outcomes.
Responsibilities
- Plan, design, program, and implement PLC, HMI, and PC-based control systems for industrial automation projects.
- Interpret customer-supplied control descriptions, conduct interviews with clients and owners, and analyze system mechanical requirements to create functional software designs.
- Design and program control systems for automated equipment, including PLCs, servo motion, robotics, machine vision, and related technologies.
- Develop highly structured, well-documented, and reliable PLC and PC programs that align with established company standards.
- Design intuitive, easy-to-navigate, and visually appealing HMI interfaces that support efficient operator interaction.
- Collaborate with other project team members to share programming responsibilities and ensure cohesive system performance.
- Develop software that supports thorough, systematic in-house testing prior to on-site commissioning.
- Thoroughly test system software before exposing it to the client to ensure quality, reliability, and safety.
- Interface with outside vendors for component selection, manufacturing coordination, and assembly support.
- Commission machines on-site to meet customer quality, performance, and cycle time requirements, including testing and startup activities.
- Ensure projects are delivered on time, within scope, and within budget while maintaining high technical standards.
- Create and maintain comprehensive project documentation throughout the project lifecycle.
- Apply strong project management and leadership skills to coordinate tasks, manage timelines, and guide technical execution.
- Multitask effectively by handling diverse assignments concurrently while maintaining quality and attention to detail.
- Travel as needed (approximately 15% annually) to customer sites for commissioning, support, and project-related activities.
- Engage in a dynamic role where daily tasks vary, supporting a wide range of automation and controls challenges.
Essential Skills
- Highly competent to expert-level PLC programming skills, including the ability to develop PLC programs from front to end.
- Strong PC programming skills, including experience with .NET for control system applications.
- Proficiency in HMI programming and design, including data logging and database-connected HMI interfaces.
- Experience with major PLC platforms such as Allen-Bradley (Rockwell) and Siemens.
- Hands-on experience with industrial robots, including 6-axis robots and platforms such as Fanuc, UR, and ABB.
- Proficiency in AC and servo motion control programming for automated equipment.
- Experience with machine vision systems and applications (4+ years).
- Experience with bar-code and RFID applications in industrial environments.
- Strong understanding of industrial communication networks and their implementation in control systems.
- Demonstrated mechanical and electrical aptitude relevant to controls engineering and automated equipment.
- At least 5+ years of experience in planning, design, programming, and implementation of PLC/HMI and/or PC-based control systems.
- At least 5+ years of experience with data logging and programming HMI interfaces and databases.
- At least 5+ years of excellent interpersonal skills with the ability to work effectively in a cross-functional team environment.
- At least 5+ years of experience managing multiple tasks and handling diverse assignments concurrently.
- At least 5+ years of project management and leadership experience in an automation or controls engineering context.
- Willingness and ability to complete projects on time and within budget.
- Ability and willingness to travel up to approximately 15% annually.
Additional Skills & Qualifications
- Experience with SCADA systems and related software tools.
- Experience with software design practices that support thorough in-house testing and reliable on-site commissioning.
- Strong documentation skills, including the ability to create and maintain comprehensive project records.
- Ability to work closely with vendors for component selection, manufacturing coordination, and system assembly.
- Strong problem-solving skills with the ability to diagnose and resolve issues during testing and commissioning.
- Comfort working in