Senior Automation/Controls Engineer

Sira Consulting, an Inc 5000 company; Florence (SC); On-site; USD 100,000 - 150,000; Full time

Job summary

Sira Consulting, an Inc 5000 company, seeks an Advanced Automation Engineer to lead PLC-based controls for manufacturing operations.

You will act as SME for PLC architecture, HMI development, motion control, robotics, and industrial networks, driving modernization and productivity improvements across the plant.

Collaborating with Operations, Maintenance, Quality, IT/OT, and external suppliers, you will guide projects from concept through commissioning to production readiness.

Qualifications

• 8+ years of experience in manufacturing automation, controls engineering, or related fields.
• Experience leading automation capital projects from concept through to production deployment.
• Expertise in PLC programming, robot programming, machine safety, and system integration.

Responsibilities

• Lead the design, development, and deployment of advanced automation and controls systems for manufacturing operations.
• Serve as the subject matter expert for PLC architecture, HMI development, motion control, robotics, industrial networks, and machine safety systems.
• Develop automation strategies supporting modernization, capacity expansion, productivity improvement, and operational excellence objectives.
• Lead automation capital projects from concept development, technical specification, and business case approval through commissioning and production stabilization.
• Perform controls architecture design, hardware specification, programming standards development, system validation, and lifecycle support planning.
• Manage industrial robot integration, robot programming, end-of-arm tooling requirements, cell optimization, troubleshooting, and preventative maintenance strategies.

Skills

PLC programming

Robotics integration

HMI development

Industrial networks

Cybersecurity basics

Job description

Advanced PLC programming and controls architecture using Rockwell/Allen-Bradley platforms.

Job Description & Skill Requirement

• Lead the design, development, and deployment of advanced automation and controls systems for manufacturing operations.
• Serve as the subject matter expert for PLC architecture, HMI development, motion control, robotics, industrial networks, and machine safety systems.
• Develop automation strategies supporting factory modernization, capacity expansion, productivity improvement, and operational excellence objectives.
• Lead automation capital projects from concept development, technical specification, and business case approval through commissioning and production stabilization.
• Perform controls architecture design, hardware specification, programming standards development, system validation, and lifecycle support planning.
• Manage industrial robot integration, robot programming, end-of-arm tooling requirements, cell optimization, troubleshooting, and preventative maintenance strategies.
• Coordinate cross-functional teams including Operations, Manufacturing Engineering, Maintenance, Quality, EHS, IT/OT, Supply Chain, and external automation suppliers.
• Lead equipment procurement activities including RFQ development, supplier evaluations, technical bid reviews, FAT, SAT, and final acceptance activities.
• Establish automation and controls standards across manufacturing operations to improve system reliability, maintainability, cybersecurity, and supportability.
• Drive digital manufacturing initiatives including IIoT connectivity, data collection, machine monitoring, remote diagnostics, and Industry 4.0 technologies.
• Support new product introductions through process automation, assembly equipment development, manufacturing system integration, and production readiness activities.
• Identify productivity improvement opportunities through robotics, vision systems, automated material handling, error-proofing, and equipment modernization.
• Analyze equipment performance metrics and implement corrective actions to improve OEE, downtime reduction, throughput, labor efficiency, and yield.
• Provide technical leadership during equipment installation, startup, debugging, safety validation, commissioning, operator training, and production ramp-up.
• Coach engineers, technicians, and maintenance personnel in automation, robotics, controls troubleshooting, and structured problem-solving best practices.

Qualifications

• 8+ years of experience in manufacturing automation, controls engineering, robotics integration, or industrial equipment development.
• Proven experience leading automation capital projects from concept and technical specification through production implementation.
• Demonstrated expertise in PLC programming, robot programming, machine safety, controls architecture, and manufacturing system integration.
• Experience supporting high-volume or complex industrial manufacturing environments with production-critical equipment.
• Experience managing automation suppliers, system integrators, equipment builders, and technical service partners