Lead Controls Engineer

Sapience Automation; Charleston (SC); On-site; USD 110,000 - 150,000; Full time

Job summary

Sapience Automation in Charleston, SC is seeking a Lead Controls Engineer to design, develop, and implement PLC programs for robotic systems and automation equipment. You will program vision systems, manage FAT tests, and lead on-site installations with remote support as needed.

The role requires a post-high-school technical degree and at least 10 years in robotics or automation, with strong communication, drawing interpretation, and fault-finding skills.

Qualifications

• Minimum of 10 years of experience in robotics or automation.
• Post-high-school technical degree is required.
• Strong written and spoken communication skills.
• Proficiency with PCs and Microsoft Office applications.
• Ability to read and interpret technical drawings.
• Troubleshooting and debugging skills related to electrical control systems.

Responsibilities

• Design, develop, and implement PLC programs for robot systems and automated equipment.
• Program peripheral devices such as vision systems and automated inspection equipment.
• Oversee FAT and on-site installation during pre-build and production phases.
• Test programs at Sapience facility and support remote operations.

Skills

Communication skills

PC proficiency

Reading drawings

Troubleshooting

Education

Technical degree

Tools

AutoCAD Electrical

E-Plan

Allen-Bradley PLCs

Siemens PLCs

Job description

Company Overview

Sapience Automation is based in Charleston, SC and is a robotics and automation systems integrator delivering automation solutions to manufacturers across North America. Recognized as a two-time FANUC Innovative System of the Year finalist (2023 and 2026), a recipient of the Outstanding Growth Award (2024 & 2025), Exemplary Sales Award (2025), and DURR Partner of the Year (2025) Sapience partners with clients in the automotive, aviation, medical, heavy truck, consumer products, food, defense, building materials, and energy industries to deploy high-performance automation systems — from single robot cells to complex, multi-process production lines.

Job Description: Lead Controls Engineer

Sapience Automation is based in Charleston, SC and is a robotics and automation systems integrator delivering automation solutions to manufacturers across North America. Recognized as a two-time FANUC Innovative System of the Year finalist (2023 and 2026), a recipient of the Outstanding Growth Award (2024 & 2025), Exemplary Sales Award (2025), and DURR Partner of the Year (2025) Sapience partners with clients in the automotive, aviation, medical, heavy truck, consumer products, food, defense, building materials, and energy industries to deploy high-performance automation systems — from single robot cells to complex, multi-process production lines.
Our application expertise spans robotic assembly, machine tending, material handling, painting, palletizing, sealing & dispensing, inspection, welding, laser marking, and traceability. We complement robot integration with custom machine and conveyor design, advanced end-of-arm tooling and vision systems. Sapience is committed to earning customers for life through skilled people, disciplined execution, and solutions that are superior in design, performance, ease of use, and support.
Sapience is an independent operating company within PPC Partners, an employee-owned business with over 3000 employees, so we offer a combination of small company flexibility with the infrastructure and investment support of a large organization. Charleston, South Carolina is a 12-time recipient of the "Best City in the US" by Travel + Leisure.

Responsibilities

• Design, develop, and implement PLC (Programmable Logic Controller) programs to control robot systems and other automated systems.
• Program peripheral devices such as vision system, RFID controllers, and automated inspection equipment.
• Execute the installation, debugging, and production launch of robot systems during the pre-build phase at Sapience and on-site installations.
• Test programs during the Factory Acceptance Test (FAT) / Modular Build phase at Sapience’s facility.
• Provide remote support to Sapience team members via remote connection.
• Proficiency with Allen Bradley PLCs and/or Siemens PLCs is required and experience with other PLCs, MES systems, or robot programming is a plus.

Control Panel and Automation Electrical & Pneumatic System Design

• Design control panels, electrical controls, safety hardware, and pneumatic controls for robot systems and automation equipment such as conveyors.
• Create detailed drawings of system designs.
• Collaborate with vendors and Sapience’s purchasing department to obtain quotes and procure necessary materials for the system.
• Oversee the panel build process to ensure compliance with specifications. Panel builds are done either internally at Sapience or through partner companies.
• Support engineers during system installation, testing, and debugging.
• Proficiency in AutoCAD Electrical and/or E-Plan required.

General

• Coordinate site teams and coordinate management on project execution.
• Coordinate subcontractors for controls programming or electrical design support.
• Create project timelines and hours estimates.
• Manage activities using the Sapience ERP system (Zoho).
• Help manage Junior Engineers and provide work assignments to them.
• Lead or participate in Engineering Processes such as FMEAs, Safety Plans, Design Reviews, and the System Verification Process.

Qualifications

In this role, you’ll need a combination of technical skills, leadership, creativity, and problem-solving abilities. Here’s what we’re looking for:

• Minimum of 10 years of experience in the robotics or automation industry.
• Post-high-school degree in a technical discipline.
• Strong written and spoken communication skills.
• Proficiency with PCs and Microsoft Office applications.
• Ability to read and interpret technical drawings.
• Troubleshooting and debugging skills related to electrical control systems.

Additional Notes

• Occasional travel to customer sites is required to support system installations and provide production support.

Sapience Automation is an Equal Opportunity Employer