Lead Controls Engineer

Sapience Automation LLC; Charleston, Northern (SC, KY); Hybrid; USD 120,000 - 160,000; Full time

Job summary

Sapience Automation LLC seeks a Lead Controls Engineer in Charleston, SC to lead PLC programming, electrical & pneumatic design, and automation projects for industrial robotics systems. You will design, develop, and deploy control solutions, supervise engineers, coordinate on-site installations, and ensure project milestones.

The role requires 10+ years in robotics/automation, strong communication, and collaboration with vendors and customers.

Qualifications

• Minimum of 10 years of experience in robotics or automation.
• Strong written and spoken communication skills.
• Proficiency with PCs and Microsoft Office.
• Ability to read and interpret technical drawings.
• Troubleshooting and debugging electrical control systems.

Responsibilities

• Design, develop, and implement PLC programs to control robot systems and automated equipment.
• Program peripheral devices such as vision systems, RFID controllers, and automated inspection equipment.
• Install, debug, and production launch of robot systems on-site and during pre-build.
• Test programs during FAT/Modular Build phases at Sapience facility.
• Provide remote support to Sapience team members.
• Design control panels, electrical and pneumatic systems; create detailed drawings.

Skills

PLC programming

Robotics/automation experience

Leadership

Communication skills

Troubleshooting

Reading technical drawings

Tools

Allen-Bradley PLCs

Siemens PLCs

AutoCAD Electrical

E-Plan

MES systems

Zoho ERP

Job description

Charleston, South Carolina, United States

Location(s)

Charleston , South Carolina , United States

About Us

Sapience Automation is an industrial robotics and systems integration company. They design, build, and program custom robotic systems for manufacturing sectors like automotive, aerospace, and consumer products.Their specific solutions include automated assembly, machine tending, precision robotic labeling, and defect inspection.

Job Description

Job Description: Lead Controls Engineer

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.

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:

PLC / Software Programming

• 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.
• 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