Controls Engineer

Helion; Dallas (TX); On-site; USD 90,000 - 120,000; Full time

Job summary

A leading engineering firm in Texas is seeking a Senior Controls Engineer to lead automation and controls projects within a manufacturing environment. This hands-on role focuses on designing, programming, and optimizing industrial control systems. Key responsibilities include troubleshooting PLC and SCADA systems, developing electrical schematics, and driving automation improvements. The ideal candidate should have a degree in Electrical or Controls Engineering and extensive experience in controls engineering within manufacturing environments.

Qualifications

• 7–12+ years of controls engineering experience in a manufacturing environment.
• Ability to troubleshoot live production systems under pressure.
• Experience with capital projects and major system upgrades.

Responsibilities

• Lead controls engineering efforts across capital and continuous improvement projects.
• Design, program, and troubleshoot PLC, HMI, and SCADA systems.
• Execute system integration, commissioning, and startup support for new equipment.

Skills

PLC programming

Electrical design

Troubleshooting under pressure

Industrial networks

Education

Bachelor’s degree in Electrical Engineering or Controls Engineering

Tools

Allen-Bradley

Siemens

Job description

We are seeking a Senior Controls Engineer to lead and execute automation and controls projects within a manufacturing environment. This role is highly project-driven, focused on designing, programming, commissioning, and optimizing industrial control systems to improve production reliability, throughput, and safety.

This is a hands‑on engineering role with ownership from concept through implementation, working closely with operations, maintenance, and project teams.

Key Responsibilities

• Lead controls engineering efforts across capital and continuous improvement projects
• Design, program, and troubleshoot PLC, HMI, and SCADA systems (Allen‑Bradley, Siemens, etc.)
• Develop and modify electrical schematics, panel designs, and control architectures
• Execute system integration, commissioning, and startup support for new equipment and production lines
• Identify and implement automation improvements to increase uptime, reduce scrap, and improve efficiency
• Support legacy system upgrades and migration to modern PLC‑controlled systems
• Perform root cause analysis (RCA) and drive corrective actions for production issues
• Collaborate cross‑functionally with operations, maintenance, and external integrators
• Ensure compliance with safety standards (NFPA, OSHA, functional safety where applicable)
• Document systems, standards, and best practices for long‑term sustainability

Required Qualifications

• Bachelor’s degree in Electrical Engineering, Controls Engineering, or related field
• 7–12+ years of controls engineering experience in a manufacturing environment
• Strong experience with:
• Electrical design, schematics, and panel layouts
• Proven experience with capital projects, line builds, or major system upgrades
• Ability to troubleshoot live production systems under pressure
• Experience with industrial networks (EtherNet/IP, Profinet, Modbus, etc.)

Preferred Qualifications

• Experience with functional safety systems / safety PLCs (FSE a plus)
• Exposure to robotics, vision systems, or advanced automation
• Experience leading projects or mentoring junior engineers
• Background in high‑volume manufacturing environments (steel, automotive, packaging, etc.)

What Success Looks Like

• You can walk into a plant and quickly diagnose system issues
• You improve systems that deliver measurable ROI (uptime, throughput, cost savings)
• You’re equally comfortable programming, troubleshooting, and working on the floor