Senior Controls Engineer

Position: Senior Controls Engineer – Advanced Automation & Industrial Systems

Location: McElhattan, PA (On-site)

Compensation: $95K - $135K

Employment: Full Time

Ready to lead cutting-edge automation projects and mentor a talented team? We're seeking a Senior Controls Engineer to design, implement, and optimize complex control systems in a high-speed manufacturing environment. This role offers the chance to work with advanced technologies, drive innovation, and make a direct impact on operational excellence. We are seeking an experienced Senior Controls Engineer for our facilities located in North Central PA (McElhattan, PA). This position specifies, designs, implements, and upgrades complex controls systems and software programming on production equipment and associated machinery. Provides mentorship and assists Controls Engineers and Technicians in solving complex problems. Will have a direct link to plant performance results through machine improvements and engineering-based upkeep.

Location: McElhattan, PA

Pay $95,000 to $135,000 (based on experience).

Key Responsibilities

• Observes OSHA and company safety rules and always uses the proper safety equipment. Identifies potentially dangerous electrical hazards and takes immediate corrective action. Demonstrates advanced National Electrical Code understanding by teaching others. Develop Safety Procedures for installed machines – Lock-Out /Tag-Out for operations and maintenance personnel.
• Leads/supports internal Engineering, Maintenance, Production, OEMs, vendors, and contractors to design, install, interface, start up new equipment and process controls. This including electrical component selection and approval, electrical design approval, software assessments & modifications, machine acceptance testing and problem identification and resolution.
• Collaborates with internal Engineering Teams, Maintenance and Production personnel, OEMs, vendors, and contractors to design, install, commission, and start up new equipment and process controls. This includes electrical and controls component selection and approval, electrical design approval, software assessments & modifications, machine acceptance testing and problem identification and resolution.
• Responsible for specifying and/or designing DCS's, PLC's, HMI's, servo systems, motors, drives, sensors, vision sensors, and data collection systems based on the FQ controls standards criteria.
• Evaluates electrical equipment from multiple sources and recommends the best solution for use.
• Assesses, designs, and makes complex program modifications in DCS's, PLC logic, HMI programs and servo controller logic to improve individual equipment and overall system performance.
• Performs high level troubleshooting, in-depth critical thinking, and utilizes all internal & external resources to solve any electrical, mechanical, or process problem.
• Leads & assists others in troubleshooting equipment, controls components and control programs.
• Works with internal MES team to develop and maintain machine data collection within the business.
• Leads small capital projects.
• Keeps abreast of new controls technologies, industry trends, health and safety regulations and standards that affect current operations.
• Proactively identifies opportunities to increase production operation performance. Initiates, leads, and oversees improvement projects through completion.
• Provides technical and operation training to Controls team, Production, Warehouse, and other personnel as needed.
• Shares knowledge and techniques with team members and coordinates the training of personnel to enhance troubleshooting skills.
• Demonstrates a sense of urgency with peers and operations personnel to maintain focused actions.
• Drives a zero-loss time mentality with team through continuous improvement practices. Keeping safety as the priority when making decisions.
• Provides direction and assistance as necessary for off shift/afterhours support.

Our Ideal candidate will possess the following experience/skills/traits-Controls Engineer

• Previous experience as a CE
• 11-17 production lines
• 8 plus years' experience in high-speed manufacturing.
• Strong leadership and technical knowledge.
• MS project and SAP knowledge.
• MES and PLC based hardware/software (Allen Bradley (preferred) and/or Rockwell and/or Siemens), industrial controls experience.
• Process controls experience, robotics experience (mantec), programming experience, and MES experience (we have a homegrown system).
• Rockwell automation – very heavy motion control, servo, and vision systems (Cognex).
• Self-directed, collaborator, confident but not arrogant, and a good communicator.
• Mentor and be able to provide day to day direction to other Controls Engineers.
• Performance based bonus (10%) and quarterly incentive plan (5%).
• Relocation assistance – case by case basis.

Education & Experience

• Bachelor's degree in the following degrees or related degrees: Electro-Mechanical Engineering, Electrical Engineering, Mechatronics, Automation Engineering, Robotics Engineering, Manufacturing Engineering.
• Able to create and modify schematic drawings using AutoCAD software.
• Minimum of 8 years' experience with Industrial Controls Systems.
• Advanced knowledge of electrical theory and principles of operation.
• Advanced knowledge of PLC based hardware and software (Rockwell and Siemens), Servo Control, and HMI.
• Knowledge of Mechanical, Pneumatic, and Hydraulic systems.
• Formal Training in Functional Machine Safety and proper safe machine design through Safety Risk Assessment.
• Knowledge or formal training in Security in Automation (ISO
• Lean Six Sigma Green Belt or Black Belt (preferred but not required).
• Root Cause Analysis Experience (preferred but not required).
• Collaborates with Maintenance, Process Engineering, Project Engineering, and Operations to define design requirements, design improvements, and install machinery and upgrades.
• Verifies communication of machine and process changes to all affected team members.
• Supports team with all key initiatives, special projects and provides exceptional customer service.
• Participates, facilitates, and leads communication in group settings and/or meetings.
• Excellent compensation and benefit package

Keywords for SEO: Senior Controls Engineer, Industrial Automation, PLC Programming, DCS Systems, Servo Control, Motion Control, Robotics Integration, Manufacturing Engineering, Troubleshooting, Preventive Maintenance.

Salary : $95,000 - $135,000