Sr Engineer, Automation Controls

Job Summary:

As product designs become increasingly miniaturized and complex, the Senior Automation Controls Engineer plays a pivotal role in delivering advanced automation solutions for high-volume, highly regulated manufacturing environments. This position is responsible for designing, developing, and deploying custom automated systems that meet stringent regulatory, quality, safety, and operational requirements.

The Senior Automation Controls Engineer works cross-functionally with design, manufacturing, quality, and process engineering teams to support the full equipment lifecycle. By integrating equipment data collection, SCADA/IoT capabilities, and Industry 4.0 best practices, this role provides data-driven manufacturing solutions that drive operational excellence and continuous improvement.

Duties & Responsibilities:

• Identify automation opportunities working closely with design, manufacturing and process engineers to conceptualize solutions.
• Manage the design, purchase, installation and validation of the Company’s custom automated solutions.
• Specify, program and troubleshoot PLC/HMI’s, industrial communications, motion control systems including servo & stepper motor control, pneumatic actuators, machine vision, robotic systems, conveyors, etc.
• Design and implement error-proofed machine interface and UIs, providing multiple levels of control to be utilized by production, maintenance and engineers.
• Design the processes and standards of data collection from equipment, hardware selection, and implementation model for the industry 4.0 program.
• Design Pilot/POC for new data collection technologies.
• Generate PLC ladder logic with an emphasis on generating code that is organized, structured, documented, maintainable, and reusable using IEC 61131-3 programming standards.
• Generate equipment/project requirements to capture the full design lifecycle of equipment to be deployed in a highly regulated environment.
• Implement reliable closed loop communications to integrate components utilizing Digital I/Os and network communications.
• Generate, display and export standard equipment performance metrics/reports in real time.
• Assist in risk assessments and implement safer solutions as per ANSI, RIA 15.06, OSHA, ISO 12100, and ISO 13849 / IEC 62061 safety standards.
• Generate, modify, and approve industrial electrical control panels which are compliant with NFPA 79, NEC, UL 508A, and IEC 60204-1, and create electrical and pneumatic schematics.
• Select, size and integrate electrical and electromechanical components such as servos, sensors, controllers, vision systems, robots, safety devices, etc.
• Provide feedback and experience in equipment design reviews.
• Retrofit controls on current deployed equipment to improve safety and enable data collection.
• Support maintenance and sustaining teams in troubleshooting difficult equipment failures.
• Participate in supplier and equipment buyoffs (FAT/SAT). 
• Create, review, and maintain all automation and controls documentation, including functional specifications, PLC/HMI software documentation, electrical and pneumatic schematics, commissioning reports, and change records in accordance with standards and company quality system requirements.
• Support design controls, validation, and regulatory documentation for automated equipment, including IQ/OQ/PQ deliverables and traceability artifacts, ensuring compliance with FDA where applicable.
• Ensure all automation designs are fully documented and traceable in alignment with internal quality systems, design controls, and applicable safety standards. 

Minimum Qualifications:

• 3+ years of experience as a hands-on Automation & Controls Engineer or Robotics Engineer working on automation and/or electromechanical systems
• Demonstrated proficiency in PLC and HMI programming, troubleshooting, and configuration
• Experience creating CAD packages and electrical schematics in accordance with IEC / NFPA documentation standards. Experience with “SolidWorks Electrical” preferred
• Demonstrated ability to configure and troubleshoot industrial network communications (Modbus TCP/IP, EtherNet/IP, EtherCAT)
• Demonstrated excellent understanding of control architecture, system integration, and motion controls applied in a manufacturing environment
• Demonstrated ability to complete multiple projects within time and budget
• Demonstrated ability to work in a team environment as well as an individual contributor
• Demonstrated excellent conceptual, analytical, and problem-solving ability
• Demonstrated ability to communicate technically both orally and in writing
• Demonstrated ability to debug and solve practical problems with minimal supervision

Preferred Qualifications: 

• 7+ years of experience as a hands-on Automation & Controls Engineer or Robotics Engineer
• Has successfully applied in-depth knowledge of Safety standards (ANSI, RIA 15.06, OSHA, ISO, IEC) for safeguarding robots, gantries, conveyors, and high-volume manufacturing equipment
• Demonstrated excellence in PLC programming with a defined methodology for code structure, state machines, fault handling, and recovery
• Has successfully implemented SQL databases to store equipment data and metrics
• Has successfully deployed control solutions using PLCs [Opto 22, Allen-Bradley, Panasonic, Beckhoff], Safety PLCs [Banner, Keyence], HMIs, sensors, remote I/O, pneumatic systems, and motor control
• Has successfully deployed industrial or collaborative robots into a manufacturing environment
• Has successfully deployed machine vision solutions
• Demonstrated ability to configure and troubleshoot industrial communication between devices (EtherNet/IP, EtherCAT, Modbus TCP/IP)
• Demonstrated in-depth knowledge of IoT or connected manufacturing concepts and predictive maintenance
• Experience optimizing and debugging systems to maximize yield, availability, and cycle time
• Demonstrated in-depth knowledge of SCADA systems through development, deployment, or maintenance
• Basic experience with machine shop equipment, measuring tools, and hand tools
• Has created successful automation solutions in startup environments and scaled them for production

Education: 

• BS/MS in Electrical Engineering (or equivalent Engineering Degree – Control Engineering, Mechatronics Engineering, Computer Engineer, Mechanical Engineering.)

Compensation: 

The anticipated salary range for this position is $115,000 - $145,000 plus benefits. Actual placement within the range is dependent on multiple factors, including but not limited to skills, education, and experience. This position also qualifies for up to 10% annual bonus based on Company, department, and individual performance.