Controls Engineer

Methods Machine Tools Inc; Sudbury (MA); On-site; USD 59,236 - 77,145; Full time

Job summary

Methods Machine Tools Inc. is seeking an Automation Controls Engineer in Massachusetts to design, develop, and support control systems that integrate CNC machine tools with peripherals and Fanuc robotic cells.

The role involves hands-on programming, troubleshooting, and optimization of PLCs, HMIs, and robotics in a manufacturing setting. The ideal candidate will have strong electrical control theory knowledge, experience with machine tools, and the ability to improve automation system

Qualifications

• Bachelor’s degree in Electrical Engineering, Automation, Mechatronics, or related field.
• Proven experience designing, programming, and maintaining control systems (PLCs, HMIs, SCADA).
• Strong knowledge of industrial control systems and automation technologies.
• Hands-on PLC programming experience with Rockwell, Siemens, Schneider, or other platforms.

Responsibilities

• Design, program, and implement control systems for automated equipment, including PLCs, HMIs, SCADA, and other automation components.
• Program and modify ladder logic for CNC machines to interface the automated equipment and ensure smooth interaction between control systems and machinery.
• Troubleshoot and resolve integration issues between CNC machines and automation equipment, including hardware failures and software bugs.
• Optimize control system performance to improve efficiency, uptime, and reliability.
• Create and maintain technical documentation for control systems, including wiring diagrams and programming manuals.
• Conduct system testing, validation, and commissioning of new control systems and automation equipment before going live.
• Collaborate with electrical, mechanical, and production teams and provide training and ongoing support for operators and maintenance staff.

Skills

Ladder Logic

Structured Text

Function Block Diagrams

HMI development

SCADA

Networking protocols

Safety PLCs

Robot programming

Fanuc robot programming

Education

Bachelor's degree in Electrical Engineering

Automation/Mechatronics related degree or equivalent experience

Tools

Rockwell RSLogix/Studio 5000

Siemens SIMATIC S7

Schneider Electric

HMI/SCADA software tools

Industrial networking tools

Job description

Description

Methods Machine Tools was established in 1958 with three employees and a handful of refurbished machines. Since then, the company has become one of the largest privately owned machine tool importers in North America.

Job Summary

The Automation Controls Engineer is responsible for designing, developing, and supporting the control systems that integrate CNC machine tools with a range of accessories and Fanuc robotic cells. This hands‑on role involves programming, troubleshooting, and optimizing control systems, such as PLCs, HMIs, and robotic systems. The ideal candidate will have experience with machine tools and a deep understanding of electrical control systems, control theory, and the ability to improve automation system performance in a manufacturing or industrial environment.

Duties / Responsibilities

• Design, program, and implement control systems for automated equipment, including PLCs, HMIs, SCADA systems, and other automation components.
• Program and modify ladder logic for CNC machines to interface the automated equipment, ensuring seamless interaction between control systems and machinery, and ensuring that automation systems operate smoothly within the broader production environment.
• Troubleshoot and resolve integration issues between the CNC machines and automation equipment, including hardware failures, software bugs, and communication problems.
• Optimize the performance of control systems to improve efficiency, uptime, and system reliability.
• Create and maintain technical documentation for control systems, including system specifications, wiring diagrams, programming manuals, and troubleshooting guides, and provide detailed reports on system performance, improvements, and project status.
• Conduct system testing, validation, and commissioning of new control systems and automation equipment, ensuring systems meet performance specifications, safety standards, and operational requirements before going live.
• Work closely with electrical engineers, mechanical engineers, automation technicians, and production teams to implement and support automation projects, and provide technical training and ongoing support for operators and maintenance staff on control systems.
• Ensure all control systems are designed and implemented in compliance with safety regulations and industry standards, participate in risk assessments, and implement safety protocols to ensure safe operation of automated systems.
• Participate in continuous improvement initiatives to enhance automation systems, reduce downtime, and improve system efficiency, and evaluate new technologies and tools to incorporate into control system designs.
• Support machine runoff, debug, and final testing of integrated systems both in‑house and at customer sites.
• Ensure automation and accessories function reliably with the CNC machine tool before delivery, addressing any control, timing, or sequencing issues.
• Collaborate closely with the applications engineering team during the design and execution of turnkey automation projects.
• Provide input on control strategies, sequencing, and system layout to ensure smooth integration between machine, accessories, and automation equipment.

Required Skills / Abilities

• Proficiency in control programming languages (e.g., Ladder Logic, Structured Text, Function Block Diagrams).
• Familiarity with HMI development and SCADA systems.
• Knowledge of electrical systems, sensors, actuators, and communication protocols (e.g., Ethernet/IP, Modbus, Profibus).
• Strong problem‑solving and analytical skills.
• Excellent written and verbal communication skills to document and explain technical concepts.
• Ability to work in a collaborative, team‑oriented environment.
• Experience with industrial networking and communication protocols (e.g., OPC, Modbus TCP/IP).
• Familiarity with machine safety standards and best practices, including safety PLCs, hard‑wired safety circuits and risk assessment requirements.
• Certification in automation or control systems (e.g., PLC programming, Six Sigma, or other relevant certifications).
• Familiarity with Fanuc robot programming, CNC machine tools or motion control systems is a plus.
• Familiarity with SolidWorks Electrical is a plus.

Minimum Education and Experience

• Bachelor’s degree in Electrical Engineering, Automation Engineering, Mechatronics, or a related field (or equivalent work experience).
• Proven experience in designing, programming, and maintaining control systems (e.g., PLCs, HMIs, SCADA).
• Strong knowledge of industrial control systems and automation technologies.
• Hands‑on experience with PLC programming (e.g., Rockwell, Siemens, Schneider, or other platforms).
• Experience with control system diagnostics, troubleshooting, and system optimization.

Supervisory Responsibilities

• None

Travel Requirements

• Up to 20% of time

Salary

$43.16 – $55.89 per hour

The listed salary range represents our good faith estimate for this position. Final compensation will be determined based on a candidate’s experience, skills, and qualifications, and may exceed the posted range for highly qualified candidates.

Physical Requirements

• Prolonged periods of sitting at a desk and working on a computer.
• Must be able to lift up to 15 pounds at times.

Additional Information

This job description is designed to provide an overview of basic skills, experiences and education required to perform the job and is not designed to cover or contain a comprehensive listing of all activities, duties, or responsibilities required of the employee to perform the essential functions of the job. In instances where educational degrees are required, the company will take into consideration factors such as additional experience, training, or certifications in lieu of specific educational requirements.

Equal Opportunity

Methods Machine is an Equal Opportunity/Affirmative Action employer. All qualified applicants will receive consideration for employment without regard to sex, gender identity, sexual orientation, race, color, religion, national origin, disability, protected Veteran status, age, or any other characteristic protected by law.