Senior Controls Engineer

Federal Mfg•Rocky Mount, NC

12d•Onsite

About The Position

The Senior Controls Engineer's primary focus is to design, program, troubleshoot, implement and test the electrical control system for automated packaging machinery. As a Senior Controls Engineer, you will lead the full project lifecycle - from functional specification analysis to final on-site commissioning - ensuring all systems meet company standards, safety regulations and customer requirements. The position reports to the Controls Engineering Manager and is located in our Rocky Mount, NC office. In this role you will... System Design & Programming: Develop and debug PLC and HMI programming (primarily Rockwell, Siemens, and Omron). Design electrical schematics and panel layouts using AutoCAD Electrical. Implement precise motor control utilizing VFDs and Servo systems. Configure Fieldbus communications (EtherNet/IP, Profinet, etc.) and data acquisition systems. Project Lifecycle & Documentation: Standards Adherence:Follow and enforce standard procedures for the creation of all technical documentation, functional specs, and training materials. BOM Management:Create and maintain accurate Bills of Material (BOM) coordinating with our ERP system to ensure project completion and procurement accuracy. Quality Control:Assist in the creation of checklists for system testing and debug phases. Engineering Change & Maintenance: ECR Evaluation:Review Engineering Change Requests (ECRs) to assess technical impact, cost, and safety. Obsolescence Management:Work with product line managers and aftermarket sales to evaluate electrical components for obsolescence; identify, test, and implement modern replacements to maintain machine longevity. Collaboration & Field Support: Coordinate directly with Production to oversee assembly and hardware integration. Travel (up to 15%) to customer locations for installation, service, and commissioning. Provide in-house and on-site technical training for employees and customers

Requirements

Bachelor of Science degree in Engineering, Technical School degree, or equivalent proven work experience in control software design.
Minimum 7 years of automation controls and programming experience.
Proficiency in AutoCAD Electrical or SolidWorks Electrical.
Working knowledge of I/O hardware, signal conditioning, field devices, sensors, and machine safety standards.
Ability to lead and work within a cross-functional team (Sales, Marketing, Engineering, Production, and Field Services) with the ability to communicate effectively in both oral and written forms.

Nice To Haves

Specific experience in packaging machinery is a significant plus.
Demonstrated literacy in ERP systems for BOM creation is a plus.

Responsibilities

Develop and debug PLC and HMI programming (primarily Rockwell, Siemens, and Omron).
Design electrical schematics and panel layouts using AutoCAD Electrical.
Implement precise motor control utilizing VFDs and Servo systems.
Configure Fieldbus communications (EtherNet/IP, Profinet, etc.) and data acquisition systems.
Follow and enforce standard procedures for the creation of all technical documentation, functional specs, and training materials.
Create and maintain accurate Bills of Material (BOM) coordinating with our ERP system to ensure project completion and procurement accuracy.
Assist in the creation of checklists for system testing and debug phases.
Review Engineering Change Requests (ECRs) to assess technical impact, cost, and safety.
Work with product line managers and aftermarket sales to evaluate electrical components for obsolescence; identify, test, and implement modern replacements to maintain machine longevity.
Coordinate directly with Production to oversee assembly and hardware integration.
Travel (up to 15%) to customer locations for installation, service, and commissioning.
Provide in-house and on-site technical training for employees and customers