Sr. Controls Engineer
About The Position
The Sr. Controls Engineer analyzes user requirements, process design, and mechanical equipment design to develop controls architectures for automated systems. The role works closely with engineers and technicians to define and conduct experiments supporting process technology development and solution design. It also collaborates with internal and external subject matter experts on project objectives and technical problem-solving, applying controls theory to complex process control and monitoring challenges. The position is based in Hickory, North Carolina, and requires 40 or more hours per week, including off-shift support as project needs require. Travel is approximately 15%, including some international travel. The position does not support immigration sponsorship.
Requirements
- Bachelor’s degree in Electrical Engineering, Mechanical Engineering, Computer Science, Computer Engineering, Physics, Optics, Mechatronics, Systems Engineering, or a related technical field.
- 6–8 years of engineering or manufacturing experience, with strong experience in automation controls, PLC/HMI programming, industrial instrumentation, machine integration, motion control, automated inspection, test systems, or related manufacturing applications.
- Experience with Omron, Allen-Bradley, or Siemens controls hardware and programming.
- Experience with motion control systems or robotics.
- Experience developing detailed controls system architecture definitions and supporting documentation.
- Experience specifying, selecting, and configuring compatible controls hardware for complete control systems.
- Strong problem-solving and decision-making skills, supported by advanced data analysis.
Nice To Haves
- Experience leading technical projects, workstreams, or major automation system elements in a cross-functional engineering and manufacturing environment.
- Experience preparing controls drawings using AutoCAD or EPlan.
- Experience writing PC-based applications in C++ or similar languages.
- Experience producing controls systems that interface with SCADA and MES systems.
- Experience performing machine safety analysis.
- Proficiency with Ladder Logic and Structured Text programming.
- Experience working with large, geographically diverse project teams.
- Proficiency in MS Office (Excel, Word, Project, PowerPoint).
- Strong understanding of computer operating systems.
Responsibilities
- Collaborate with cross-functional teams to translate process requirements into control system designs, methodologies, and documentation that ensure process quality.
- Produce controls architecture documentation that communicates requirements to internal teams, external partners, and vendors.
- Interface with vendors to evaluate and select components for equipment development.
- Develop code to provide required functionality for equipment under development.
- Design PC-based Human Machine Interfaces (HMIs) for machine control and operator feedback.
- Partner with internal IT resources to implement network connectivity and permissions that support equipment functionality.
- Debug, modify, and improve new and existing equipment to support development activities.
- Work with mechanical designers and controls technicians to resolve issues and guide best practices.
- Coordinate with controls resources to keep hardware, software, and related documentation aligned through change management processes.
- Design and execute test plans to validate equipment performance and prepare written reports summarizing results.
- Perform safety analyses and compliance assessments to identify risks and ensure adherence to applicable standards, policies, and regulatory requirements.
Benefits
- Company-wide bonuses and long-term incentives.
- 100% company-paid pension benefit with fixed contributions.
- Matching contributions to the 401(k) savings plan; combined retirement contributions can reach 7%–12% of pay, depending on age and years of service.
- Medical, dental, and vision benefits.
- Paid parental leave and family building support.
- Fitness benefits.
- Company-paid life insurance and disability benefits.
- Disease management programs.
- Paid time off.
- Employee Assistance Program (EAP).
- Recognition program to celebrate successes and reward exceptional contributions.
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What This Job Offers
Job Type
Full-time
Career Level
Senior
