Sr. Controls Engineer

VulcanForms Inc.•Devens, MA

1d•$105,515 - $145,083

About The Position

VulcanForms is seeking a Senior Controls Engineer – Factory Automation to join its Engineering team in Devens, Massachusetts. The role leads the development of automated machinery for production processes, from concept through qualification, and focuses on designing, developing, and deploying automation tailored to VulcanForms’ production processes. The position also integrates automated equipment with the company’s SCADA system, with emphasis on data acquisition, performance monitoring, and user interfaces. The engineer provides technical leadership for manufacturing operational technology systems, including HMI and SCADA platforms, industrial networks, data-collection and application servers, databases, and interfaces to plant and enterprise applications. The role defines architecture across PLC, HMI, SCADA, edge, historian, and MES layers; develops secure production-system interfaces; and leads equipment integration, troubleshooting, acceptance testing, commissioning, and validation.

Requirements

Bachelor’s degree in Electrical Engineering, Mechanical Engineering, Robotics, or a related field.
At least 7 years of direct experience as a controls engineer working on automated processes and system integration.
Advanced experience designing and building automation control systems, including PLC and SCADA.
Proven ability to troubleshoot control systems, hardware, and components in fast-paced, high-intensity environments.
Solid understanding of industrial control panel design and fabrication, including UL508A.
Solid understanding of instrumentation and controls (I&C), including field instrumentation and control-system installation and configuration.
Solid understanding of engineering documentation, including P&IDs, process flow diagrams, and standard operating procedures.
Knowledge of single- and multi-axis coordinated motion control.
Strong understanding of TCP/IP-based communication protocols, industrial networks, and system integration concepts.

Nice To Haves

Advanced experience with Siemens and Ignition.

Responsibilities

Collaborate with cross-disciplinary engineering teams on automated machinery design.
Size and select control-system components, and independently develop technical specifications, parameter lists, and engineering documentation for project implementation.
Provide technical leadership for the design, integration, implementation, and lifecycle support of manufacturing OT systems, including HMI and SCADA platforms, industrial networks, data-collection and application servers, databases, and interfaces between equipment and plant or enterprise applications.
Define architecture spanning PLC, HMI, SCADA, edge, historian, and MES layers.
Design secure, resilient interfaces for production commands, machine states, alarms, recipes, quality parameters, and confirmations.
Architect machine-to-SCADA and MES-to-machine connectivity using OPC UA, MQTT, APIs, industrial protocols, and event-driven patterns.
Integrate manufacturing equipment into the broader OT environment, using knowledge of PLCs, equipment controls, industrial communications, and machine-level data to define interface requirements.
Coordinate with equipment suppliers and system integrators throughout design, build, and installation.
Test, maintain, and integrate controls software algorithms and automation hardware components.
Lead troubleshooting, technical acceptance testing, commissioning, and system validation to ensure reliable performance and successful project delivery.