Controls Engineer

Sterling Engineering; Buffalo Grove (IL); On-site; USD 150,000 - 175,000; Full time

Job summary

A leading engineering firm is seeking a Senior Controls Engineer to join their Medical Devices team in Buffalo Grove, IL. This role involves specifying, designing, and maintaining advanced automation equipment tailored for manufacturing needs. Candidates should possess over 10 years of experience in medical device or pharmaceutical environments, a mastery of control systems, and strong programming skills in PLCs and robotics. The position offers a competitive salary ranging from $150,000 to $175,000, reflecting the level of expertise required.

Qualifications

• 10+ years of relevant experience in medical device or pharmaceutical manufacturing.
• Strong knowledge of automation equipment specification, installation, and upgrades.
• Experience designing fail-safe electrical circuits with safety PLCs and relays.

Responsibilities

• Design, develop, implement, and maintain control systems for manufacturing equipment.
• Build standardized automation cells and custom automated solutions from concept to deployment.
• Configure, program, and maintain PLC software and wiring.

Skills

PLC programming

Robotics programming

Automation solutions

Electrical design

Troubleshooting automation systems

HMI design

Python programming

Education

Bachelor’s or Master’s degree in Electrical/Electronics Engineering

Tools

AutoCAD

SolidWorks

GX Works3

Studio 5000

TIA Portal

TwinCat3

Job description

Senior Controls Engineer - Medical Devices

Compensation: $150,000 – $175,000

Overview

We are seeking a Senior Controls Engineer to join our Medical Devices team in Buffalo Grove, IL. Reporting to the Director of Operations Engineering, this role is responsible for specifying, designing, and maintaining advanced automation equipment, tooling, and applications to meet manufacturing requirements. The ideal candidate will have deep expertise in control systems, PLC programming, robotics, and automation solutions within medical device or pharmaceutical environments.

Key Responsibilities

• Design, develop, implement, and maintain control systems for manufacturing equipment.
• Build standardized automation cells and custom automated solutions from concept to deployment.
• Configure, program, and maintain PLC software and wiring.
• Program controls for factory automation equipment including robotics, machine vision, servos, and pneumatics.
• Work with multiple PLC platforms (Mitsubishi, Allen-Bradley, Siemens, Beckhoff, Omron, etc.), HMIs, and motion controllers.
• Perform electrical design, drafting, and communication architecture for automation systems.
• Troubleshoot and resolve automated process or equipment issues.
• Develop and improve manufacturing processes and equipment for electrical component assembly.
• Partner with vendors and maintenance teams to ensure spare parts availability and preventive maintenance plans.
• Support system deployment at company and customer sites, including service work.
• Collaborate with engineers, designers, and operations leadership on automation initiatives.

Qualifications

• Bachelor’s or Master’s degree in Electrical/Electronics Engineering or related field.
• 10+ years of relevant experience in medical device or pharmaceutical manufacturing.
• Strong knowledge of automation equipment specification, installation, and upgrades.
• Experience designing fail-safe electrical circuits with safety PLCs and relays.
• Robotics programming experience with UR, ABB, Omron, or Yamaha.
• Expertise in PLC programming (Structured Text, Ladder Logic) and software tools such as GX Works3, Studio 5000, TIA Portal, TwinCat3.
• M HMI design experience (FactoryTalk, GTWorks3, or similar).
• Skilled in integrating mechanical, electrical, sensor, and pneumatic/hydraulic systems.
• Proficiency with AutoCAD, SolidWorks, or equivalent for schematics/drawings.
• Python programming and IoT device familiarity a plus.
• Experience with BOMs, manufacturability, process design, and continuous improvement methodologies.
• Background in high-speed/high-accuracy automation solutions preferred.
• Experience with fluid filling, drug handling automation, and disposable manufacturing is a strong plus.
• Ability to manage multiple projects and communicate effectively across teams.

Qualified applicants will receive consideration for employment without regard to race, color, age, religion, sex, sexual orientation, gender identity, national origin, disability, protected veteran status, or genetic information.