Controls Engineer

Insight Global; North Carolina; Hybrid; USD 110,000 - 150,000; Full time

Job summary

Insight Global in North Carolina is seeking a Sr. Controls Engineer (FAT/SAT & Commissioning) for a rapidly growing advanced manufacturing client.

This engineer will own the automation acceptance process across a major facility expansion, serving as the bridge between OEMs, system integrators, and automation vendors. The ideal candidate can write and troubleshoot PLC code while driving FAT/SAT execution, equipment acceptance, and multi-vendor integration, with travel required.

Qualifications

• Experience with FAT and SAT procedures.
• Ability to read schematics and PLC code.
• Travel up to 50% domestically.
• Cross-vendor system integration experience.

Responsibilities

• Lead automation acceptance, FAT, SAT, and commissioning activities for a large manufacturing expansion.
• Develop standardized FAT/SAT protocols and manage program-wide punch lists.
• Review OEM controls architectures, schematics, PLC code, and HMI designs.
• Program, modify, troubleshoot, and commission Siemens and Rockwell PLCs.
• Coordinate integration of robotics, conveyors, AGVs, vision systems, servos, and material handling equipment.
• Validate controls, safety interlocks, alarms, networking, and system functionality.
• Partner with OEMs, Tier 2 vendors, and system integrators to ensure successful deployment.
• Support MES/SCADA connectivity and automation system performance.
• Serve as the senior escalation point for complex controls and commissioning issues

Skills

PLC programming

FAT/SAT expertise

Controls integration

Troubleshooting

Project coordination

Tools

Siemens PLCs

Rockwell PLCs

HMI design

Job description

JOB DESCRIPTION

Day-to-Day:

• Lead automation acceptance, FAT, SAT, and commissioning activities for a large manufacturing expansion
• Develop standardized FAT/SAT protocols and manage program-wide punch lists
• Review OEM controls architectures, schematics, PLC code, and HMI designs
• Program, modify, troubleshoot, and commission Siemens and Rockwell PLCs
• Coordinate integration of robotics, conveyors, AGVs, vision systems, servos, and material handling equipment
• Validate controls, safety interlocks, alarms, networking, and system functionality
• Partner with OEMs, Tier 2 vendors, and system integrators to ensure successful deployment
• Support MES/SCADA connectivity and automation system performance
• Serve as the senior escalation point for complex controls and commissioning issues Job

*Must be open to 50% travel around the US, with potential for international travel as well*

Description: Insight Global is seeking a Sr. Controls Engineer (FAT/SAT & Commissioning) for a rapidly growing advanced manufacturing client in North Carolina. This engineer will own the automation acceptance process across a major manufacturing facility expansion, serving as the bridge between OEMs, system integrators, and automation vendors. The ideal candidate is a commissioning-focused controls engineer who can both write and troubleshoot PLC code while driving FAT/SAT execution, equipment acceptance, and multi-vendor integration efforts. This role is highly visible, highly technical, and ideal for someone who enjoys travel, commissioning, complex automation systems, and ensuring equipment is production-ready before launch.