Process Controls and Automation Engineer

Title:

Sr Controls Engineer

Position Overview:

The Sr. Controls Engineer will serve as a senior technical expert for automation and controls initiatives across manufacturing operations. This role focuses on developing, optimizing, and supporting automation systems to ensure safety, reliability, and high performance. The ideal candidate has deep expertise in PLC programming, SCADA/HMI systems (Ignition, Wonderware, or Rockwell FactoryTalk), robotics integration, and strong industrial segmentation skills to support secure, well-structured control networks and architectures.

Key Responsibilities

Automation Systems Design & Implementation

Design, develop, and implement automation and control solutions for manufacturing equipment and processes.

• Program, configure, and troubleshoot PLCs (Allen-Bradley, Siemens, etc.), HMIs (Ignition, Wonderware, FactoryTalk View), and SCADA systems.
• Integrate robotics, motion control, and vision systems into automated production lines.
• Apply segmentation strategies to control architectures to ensure reliable communication, optimized performance, and proper separation between machine, supervisory, and enterprise systems.

Project Execution

Execute automation and controls projects from concept through commissioning.

• Develop scopes of work, timelines, and technical documentation.
• Collaborate with mechanical, electrical, IT, and process engineering teams to deliver integrated automation solutions.

System Support & Optimization

Maintain, troubleshoot, and enhance control systems for safety, reliability, and efficiency.

• Develop documentation, standards, and best practices for controls systems, including network and controls segmentation guidelines.
• Diagnose hardware, software, and communications issues using advanced troubleshooting and segmentation techniques.
• Use segmentation principles to isolate issues, improve diagnostics, and reduce system downtime.

Innovation & Continuous Improvement

Identify opportunities to improve automation system performance and reliability.

• Stay up to date with emerging technologies in controls, networking, segmentation, cybersecurity, and industrial IoT.
• Implement segmentation best practices—such as cell/area zoning, VLAN grouping, and layered system design—to enhance security and improve system stability.

Qualifications

Bachelor’s degree in Electrical Engineering, Controls Engineering, Mechatronics, or related field.

• 7+ years of experience in industrial automation or process controls.
• Expert-level experience with PLCs (Allen-Bradley ControlLogix preferred), HMIs, and SCADA systems (Ignition, Wonderware, FactoryTalk, etc.).
• Experience with industrial networking (EtherNet/IP, Modbus TCP/IP, OPC-UA) and cybersecurity best practices, including industrial segmentation.
• Hands-on experience with robotics systems (Fanuc, ABB, or similar).
• Strong troubleshooting, analytical, and communication skills.
• Ability to deliver complex automation solutions and support high-reliability production environments.

Preferred Skills

Experience in high-volume or process-driven manufacturing environments.

• Knowledge of Python, SQL, or other scripting languages for data integration.
• Familiarity with safety PLCs, servo systems, and VFDs.
• Experience implementing segmentation frameworks (cell/area zones, VLAN segmentation, Purdue Model, ISA/IEC 62443).
• PMP or equivalent project management exposure is a plus.

Job Types: Contract, Permanent

Work Location: In person

Job Types: Contract, Temp-to-hire

Pay: $70.00 - $85.00 per hour

Work Location: In person