Senior Automation Engineer

Sterling Engineering; Crossville (TN); On-site; USD 110,000 - 125,000; Full time

Benefits offered by this job

No travel required

Job summary

Sterling Engineering in Crossville, TN, is seeking a Senior Controls & Automation Engineer to lead modernization efforts, troubleshoot complex controls, and guide projects from concept to startup. You will collaborate with production, maintenance, and external integrators to drive reliability and performance improvements across manufacturing operations.

The role emphasizes hands-on controls engineering, leadership in project coordination, and the development of robust documentation and

Qualifications

• Associate or bachelor’s degree in Controls Engineering, Electrical Engineering, Automation, Mechatronics, or a related technical field preferred.
• 7–10 years of industrial automation experience in high-volume manufacturing or similar environments.
• Strong experience with SCADA platforms such as Ignition, Movicon, Citect, or WinCC.
• Strong PLC programming experience with Siemens, Omron, or Allen‑Bradley/Rockwell systems.
• HMI experience with platforms such as Weintek, WinCC Advanced/Flexible, Pro‑face, or Omron.

Responsibilities

• SCADA modernization and migration to Ignition.
• Standardize backups, recovery procedures, and software change traceability for PLCs.
• Improve visibility into project progress, system performance, workload, and deadlines.
• Resolve complex automation issues and implement improvements across manufacturing operations.
• Coordinate automation projects, managing scope, workloads, timelines, deadlines, deliverables, and project status.
• Lead advanced troubleshooting and root cause analysis affecting production, quality, safety, and equipment availability.
• Perform system integration, testing, debugging, commissioning, and startup for reliable automation systems.
• Develop and maintain control system documentation, technical standards, software backups, and troubleshooting guides.
• Collaborate with production and maintenance to improve equipment reliability and manufacturing performance.
• Monitor project progress and system performance and identify opportunities for continuous improvement.

Skills

SCADA modernization

PLC programming

HMI experience

Root cause analysis

Automation performance management

Education

Bachelor's/Associate degree in Controls/Electrical/Automation/Mechatronics

Tools

Ignition

Movicon

Citect

WinCC

Siemens PLC

Omron PLC

Allen-Bradley/Rockwell

Weintek

WinCC Advanced/Flexible

Pro-face

Industrial drives

Job description

Title: Senior Controls & Automation Engineer

Location: Crossville, TN

Position Type: Full-Time Direct Hire

Salary: $110,000–$125,000 per year

No Travel Required

You’ll serve as a technical leader responsible for improving equipment reliability, troubleshooting complex control systems, and modernizing legacy automation technology. This position combines hands‑on controls engineering with project coordination and technical leadership. You’ll work closely with production, maintenance, engineering, and external integrators while driving improvements that directly support manufacturing performance.

Key Responsibilities

• SCADA Modernization: Redevelop legacy SCADA applications and migrate systems to Ignition.
• PLC Backup & Version Control: Standardize backups, recovery procedures, and software change traceability.
• Automation Performance Management: Improve visibility into project progress, system performance, workload, and deadlines.
• Production Support & Continuous Improvement: Resolve complex automation issues and implement improvements across manufacturing operations.
• Coordinate automation projects, managing scope, workloads, timelines, deadlines, deliverables, and project status.
• Lead advanced troubleshooting and root cause analysis for issues affecting production, quality, safety, and equipment availability.
• Perform system integration, testing, debugging, commissioning, and startup to ensure reliable and maintainable automation systems.
• Develop and maintain control system documentation, technical standards, software backups, and troubleshooting guides.
• Collaborate with production and maintenance teams to improve equipment reliability and manufacturing performance.
• Monitor project progress and system performance while identifying opportunities for continuous improvement.

Qualifications

• Associate or bachelor’s degree in Controls Engineering, Electrical Engineering, Automation, Mechatronics, or a related technical field preferred.
• 7–10 years of industrial automation experience, ideally in high-volume manufacturing with fast cycle times or continuous production.
• Strong experience with SCADA platforms such as Ignition, Movicon, Citect, or WinCC.
• Strong PLC programming experience, ideally with Siemens, Omron, or Allen‑Bradley/Rockwell systems.
• HMI experience with platforms such as Weintek, WinCC Advanced/Flexible, Pro‑face, or Omron.
• Experience configuring drives, industrial communication networks, and integrated control systems.

We are an Equal Opportunity Employer and consider all qualified applicants for employment without regard to race, color, religion, sex, sexual orientation, gender identity, national origin, age, disability, protected veteran status, or any other characteristic protected by applicable federal, state, or local law.