Senior Controls Engineer

Job description

We are seeking a highly skilled and experienced Senior Controls Engineer with a strong background in industrial automation and a deep expertise in CoDeSys for PLC programming. The successful candidate will play a critical role in the design, development, implementation, and commissioning of complex control systems for our [products/systems/manufacturing processes]. This role requires a hands-on approach, strong problem-solving skills, and the ability to lead technical initiatives while mentoring junior engineers, all with a keen understanding of manufacturing principles and operational efficiency. ________________________________________ Key Responsibilities: System Design & Architecture: • Lead the conceptualization, design, and specification of complex control systems, including hardware selection (PLCs, HMIs, drives, sensors, actuators) and network architecture. • Develop detailed electrical schematics, I/O lists, and wiring diagrams in collaboration with electrical engineers. • Define control strategies, safety interlocks, and operational sequences, always considering manufacturing process flow, cycle time optimization, and overall equipment effectiveness (OEE). CoDeSys Programming & Development (Core Responsibility): • Expertly program, test, and debug PLC logic using CoDeSys (IEC 61131-3) in various languages (ST, FBD, LD, SFC). • Develop and implement reusable CoDeSys libraries, function blocks, and structured text routines, ensuring solutions are robust, maintainable, and scalable for production environments. • Integrate and configure various fieldbus protocols (e.g., EtherCAT, PROFINET, Modbus TCP/IP, CANopen) within the CoDeSys environment. • Develop and integrate HMI/SCADA applications using CoDeSys visualization or other compatible platforms, prioritizing operator usability, process visibility, and diagnostic capabilities for manufacturing personnel. Commissioning & Troubleshooting: • Lead the on-site commissioning, testing, and tuning of control systems, ensuring optimal performance and adherence to specifications, with a focus on achieving production targets and minimizing downtime. • Perform advanced troubleshooting and diagnostics of complex hardware and software issues, often under pressure in a live manufacturing environment. • Collaborate with mechanical, electrical, and software engineers to resolve system integration challenges, understanding their impact on the manufacturing line •Documentation & Standards: • Create and maintain comprehensive technical documentation, including functional specifications, design documents, test plans, and as-built drawings, which are essential for long-term manufacturing support and maintenance. • Ensure all control system designs and implementations comply with relevant industry standards (e.g., UL, CE, NFPA, ISO, ANSI) and manufacturing specific regulations. • Adhere to established coding standards and best practices for CoDeSys development. Project Leadership & Mentorship: • Lead technical aspects of projects, including scope definition, scheduling, and resource allocation, considering production timelines and resource availability within a manufacturing context. • Provide technical guidance and mentorship to junior controls engineers, fostering their development in CoDeSys and control system design with an emphasis on practical manufacturing applications. • Participate in design reviews and provide constructive feedback. Continuous Improvement & Manufacturing Optimization: • Stay abreast of new technologies, industry trends, and best practices in industrial automation and CoDeSys, specifically those applicable to improving manufacturing processes and efficiency. • Proactively identify opportunities for process improvement, standardization, cost reduction • Education: Bachelor's degree in Electrical Engineering, Mechatronics Engineering, Computer Engineering, or a closely related engineering discipline from an accredited university. Master's degree a plus. • Experience: Minimum of 7+ years of progressive experience in industrial control systems design, programming, and commissioning, with a significant portion in manufacturing or production environments. • Minimum of 3+ years of dedicated, hands-on experience programming and developing complex applications with CoDeSys (all versions/compatible platforms are valuable) for industrial machinery or production lines. • Proven experience leading technical aspects of control system projects, from concept to production readiness.\ • Technical Skills (Must-Haves): Expert-level proficiency in CoDeSys (IEC 61131-3) programming. • Strong understanding of industrial networking protocols (e.g., EtherCAT, PROFINET, Modbus TCP/IP, CANopen, Ethernet/IP). • Proficient with HMI/SCADA development and integration, with an emphasis on intuitive operator interfaces and robust data acquisition for manufacturing analytics. • Solid understanding of electrical control panel design principles and safety standards (e.g., NFPA 79, UL 508A, EN ISO 13489, IEC 60204), and their application in a manufacturing plant. • Experience with industrial safety systems (e.g., safety PLCs, light curtains, emergency stops) as applied to production equipment and personnel safety. • Familiarity with CAD software for electrical design (e.g., AutoCAD Electrical, EPLAN). • Ability to read and interpret complex electrical schematics and mechanical drawings. • Demonstrated understanding of manufacturing processes, including but not limited to: material handling, assembly, machining, packaging, process control, and quality inspection. • Knowledge of key manufacturing metrics such as OEE, cycle time, throughput, and their impact on control system design. • Soft Skills: Excellent analytical and problem-solving abilities, particularly in diagnosing and resolving production issues. • Strong written and verbal communication skills, able to convey complex technical information to production, maintenance, and management teams. • Ability to w