Senior Controls Engineer – Industrial Automation

IPS Custom Automation • Arlington, TX

19h

About The Position

IPS Custom Automation is a leading provider of advanced manufacturing solutions for the defense and energetics industries. We specialize in the design, engineering, and integration of turnkey production lines for energetics materials and munitions. Our solutions serve government agencies, military contractors, and defense OEMs worldwide. IPS is seeking an experienced Senior Automation Controls Engineer to design, develop, and support complex industrial automation systems. This role is ideal for a technical leader who thrives in multidisciplinary environments and can take full ownership from conceptual design through commissioning and post‑installation support. The individual will collaborate closely with project managers, mechanical engineers, software developers, and will interface directly with clients and stakeholders. The selected candidate will lead on‑site commissioning efforts, troubleshoot complex systems, and perform final system validation. This role is critical in ensuring reliable, safe, and efficient automation solutions that meet rigorous customer and regulatory requirements while supporting production goals and continuous improvement initiatives. Experience with SCADA systems is a strong plus.

Requirements

• 10+ years of experience in industrial automation, including at least 5 years in large‑scale custom automation projects
• Demonstrated expertise in Allen‑Bradley PLC programming (Studio 5000)
• Proficiency with AutoCAD Electrical
• Experience developing HMI user interfaces (e.g., PanelView or similar platforms
• Strong understanding of control panel design, electrical systems, and industrial wiring standards
• Familiarity with machine safety standards (ISO 13849, ANSI/RIA, NFPA 79)
• Knowledge of automation components: VFDs, sensors, motion control systems, safety systems, and communication networks
• Proven ability to troubleshoot and resolve complex automation issues in production environments
• Strong analytical and problem‑solving abilities
• Effective collaboration, communication, and documentation skills across engineering, manufacturing, leadership, and client teams
• Ability to manage multiple projects and priorities simultaneously
• Willingness to travel (~10% during design phases; up to 50%+ during commissioning)
• Self‑motivated with a continuous‑improvement mindset

Nice To Haves

• Bachelor’s degree in Electrical Engineering, Mechatronics, Automation, or related field
• Experience developing or implementing SCADA systems (Ignition, AVEVA Edge/InduSoft, FactoryTalk View, Wonderware, etc
• Experience with machine vision or advanced inspection technologies
• Hands‑on robot programming experience (Fanuc, ABB, KUKA, etc)
• Experience with machine learning–based inspection (optional, depending on focus)
• Demonstrated technical leadership, ownership, and accountability
• Project management or system‑integration experience
• Background working on DoD or government-funded automation systems

Responsibilities

• Develop, program, test, and troubleshoot Allen‑Bradley PLCs (ControlLogix, CompactLogix, MicroLogix, etc)
• Create and modify ladder logic, structured text, and function block routines
• Perform system commissioning and support automation upgrades
• Program, configure, and optimize industrial robots (Fanuc, ABB, KUKA, or similar)
• Integrate robotics, third‑party solutions, and vision systems, ensuring seamless communication with PLCs and SCADA platforms
• Support robotic applications for assembly, material handling, packaging, and custom automation
• Perform robot teaching, path refinement, and cycle‑time optimization for complex motion systems
• Coordinate with vendors, integrators, and subcontractors for panel builds, robotic integration, and SCADA development
• Apply relevant standards such as UL 508A, NFPA 79, ISO 13849, and DoD cybersecurity requirements as applicable
• Size, select, and specify motors, drives, sensors, safety components, and other automation hardware
• Design electrical control panels including schematics, layouts, and component selection
• Produce documentation such as wiring diagrams, bills of materials, and panel build instructions
• Support and direct internal or external panel build technicians during assembly and fabrication
• Collaborate with and oversee external system providers to ensure design requirements and schedules are met
• Integrate PLCs, robots, HMIs, sensors, drives, and related automation equipment
• Implement networks and communication protocols (EtherNet/IP, DeviceNet, PROFINET, EtherCAT, etc)
• Ensure compliance with safety, regulatory, and machine‑guarding requirements

Benefits

• Competitive base salary (commensurate with experience) and performance-based incentives
• Generous employer contribution to the Employee portion of medical insurance (75+%)
• Dental, Vision, and Gap insurance offered
• Employer-paid Life insurance and Short-Term Disability
• 401(k) employer match and immediately vested
• Generous paid time off policy

What This Job Offers

• Job Type: Full-time
• Career Level: Senior