Senior Controls Engineer

The Senior Controls Engineer is responsible for supporting the controls design, PLC/HMI development, and implementation of electrical control systems and automation software for conveyor and sortation systems in the material handling industry (including parcel, baggage handling, warehouse distribution, and manufacturing).

You will support controls design activities, PLC/HMI programming, and commissioning/deploying jobsite activities, while mentoring controls and commissioning engineers. The position requires a hands-on, detail-oriented engineer with strong leadership, communication, and problem-solving skills to ensure successful project execution within scope, budget, and timeline.

Roles and Responsibilities

Support the design and implementation of electrical and control systems for automated material handling projects.

Develop and implement PLC and HMI programs (primarily Rockwell Automation; Beckhoff and Codesys experience a plus).

Collaborate with mechanical, electrical, and software engineering teams to define requirements and deliver integrated system solutions.

Manage and mentor controls and commissioning engineers, providing technical guidance and performance feedback.

Participate in system integration, testing, and on-site commissioning, ensuring successful start-up and customer acceptance.

Provide feedback to software development teams and improve standard PLC control libraries, templates, and best practices across projects.

Coordinate and communicate with software development teams to ensure PLC/HMI software is developed in alignment with established in-house standards.

Collaborate with stakeholders (project management, operations, and customers) to align designs with business and project goals.

Troubleshoot, diagnose, and resolve control system issues in production and commissioning phases.

Stay current with emerging automation technologies, industrial networking standards, and software development practices.

Required Skills and Attributes

Strong knowledge of industrial automation, controls architecture, and material handling systems.

Expertise with PLC platforms (Rockwell ControlLogix, CompactLogix) and HMI software (FactoryTalk View, Ignition, Aveva, Indusoft).

Solid understanding of network communication protocols: EtherNet/IP, DeviceNet, Profibus, Profinet, ControlNet.

Familiarity with VFDs (Rockwell, Siemens, Schneider, Lenze) and motion control applications.

Strong analytical and troubleshooting skills, with the ability to travel for project installation and support.

Excellent communication, leadership, and mentoring abilities.

Self-motivated, organized, and adaptable to fast-paced project environments.

Education and Experience

Bachelor’s Degree in Electrical Engineering, Electrical Engineering Technology, or related discipline (Master’s preferred).

7+ years of experience in controls system design, PLC/HMI development, site commissioning and electrical engineering for material handling or automation systems.

Experience with system commissioning.

Key Competencies

Technical Leadership & Mentorship

Critical Thinking & Problem Solving

Project Management & Scheduling

Flexibility & Adaptability

Customer-Focused Mindset

Strong Work Ethic and Professionalism