Controls Engineer (Senior)

Sterling Engineering Inc.; Buffalo Grove (IL); On-site; USD 66,000 - 110,000; Full time

Job summary

Sterling Engineering Inc. in Buffalo Grove, IL is seeking a hands-on Controls Engineer to design, program, commission, and support complex automated manufacturing systems from concept to installation.

You will lead PLC development using Allen-Bradley controls, design electrical hardware, and collaborate with mechanical and software teams to ensure high-quality, on-time project delivery. Occasional travel to customer sites is required.

Qualifications

• Bachelor's degree in Engineering or equivalent experience.
• OEM/custom automation experience preferred.
• Experience writing PLC programs from scratch.
• Strong understanding of electrical controls and industrial automation.
• Experience with Allen-Bradley/Rockwell PLCs (ControlLogix/CompactLogix).
• Familiarity with machine vision systems and industrial networking.
• Knowledge of NFPA 79 and UL 508A.
• AutoCAD Electrical experience a plus.
• Strong troubleshooting and problem-solving skills.
• Ability to work with software, logic, and complex automated systems.

Responsibilities

• Lead controls projects from concept to installation and commissioning.
• Develop and program PLC control systems for custom equipment.
• Design industrial control systems and electrical hardware.
• Develop and modify machine control software.
• Collaborate with mechanical, electrical, software, and project teams.
• Support startup, debugging, and troubleshooting at customer sites.
• Commission equipment and provide customer training.
• Create controls documentation and end-user instructions.
• Ensure projects meet schedule and budget.
• Configure and troubleshoot industrial Ethernet networks.
• Support robotics and machine vision applications.
• Occasional travel to customer sites for installation and training.

Skills

PLC programming

Automation systems

Electrical troubleshooting

Allen-Bradley PLCs

Machine vision

Industrial networks

Education

Bachelor's degree in Engineering

Tools

AutoCAD Electrical

Job description

Job Description

Job Description
Job Title: Controls Engineer Location: Buffalo Grove, IL
Job Type:Full-Time
Compensation: Up to $110,000/year
Travel: Minimal; any travel is planned well in advance
About the Role: We are seeking a hands-on Controls Engineer with experience in OEM/custom automation to design, program, commission, and support complex automated manufacturing systems. This is an excellent opportunity for an engineer who enjoys working on projects from concept and electrical design through PLC programming, machine startup, commissioning, and customer installation.
What You'll Do:

• Lead controls engineering projects from concept and design through installation and commissioning
• Develop and program PLC control systems for custom automated equipment
• Design industrial control systems and electrical hardware
• Develop and modify machine control software
• Work cross-functionally with mechanical, electrical, software, and project engineering teams
• Support machine integration, startup, debugging, and troubleshooting
• Commission equipment and provide customer training
• Develop complete controls documentation and end-user instructions
• Ensure projects are completed on schedule and within budget
• Configure and troubleshoot industrial Ethernet networks
• Support robotics and machine vision applications
• Occasionally travel to customer sites for installation, commissioning, training, and troubleshooting

What We're Looking For

• Bachelor's degree in Engineering or equivalent experience
• OEM/custom automation experience is strongly preferred
• Experience writing PLC programs from scratch
• Strong understanding of electrical controls and industrial automation
• Experience with Allen-Bradley/Rockwell PLCs, particularly ControlLogix and CompactLogix
• Experience with machine vision systems
• Experience with industrial networking/Ethernet
• Knowledge of NFPA 79 and/or UL 508A
• Experience with AutoCAD Electrical is a plus
• Strong electrical theory and troubleshooting skills
• Ability to understand and work with software, logic, and complex automated systems
• Strong problem-solving skills and curiosity for understanding how machines work

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.