Senior Controls Engineer

Insight Global; Aiken (SC); On-site; USD 90,000 - 110,000; Full time

Benefits offered by this job

Medical insurance

Dental insurance

Vision insurance

HSA

FSA

401k retirement plan

Job summary

Insight Global is seeking a Senior Controls Engineer for their Aiken, SC facility. You will support a high-volume automotive molding and assembly operation, working with PLCs, robotics, vision systems, VFDs, hydraulics, and MES.

The role mixes hands-on troubleshooting with project work to improve uptime, process reliability, and machine performance across a 24/7 environment. Collaboration with Maintenance, Production, and Engineering is essential.

Qualifications

• 2+ years of hands-on controls/automation in a production setting.
• Experience troubleshooting and modifying PLC programs.
• Experience supporting automated equipment and production lines.
• Ability to troubleshoot PLCs, VFDs, motors, sensors, hydraulics, and machine controls.
• Understanding vision systems interaction with PLCs and robotics.

Responsibilities

• 40% production support and 60% project work in a 24/7 facility.
• Troubleshoot line-down issues and drive automation improvements.
• Manage capital projects and equipment upgrades across molding and assembly operations.
• Collaborate with Maintenance, Production, and Engineering teams to improve uptime and machine performance.

Skills

PLC programming

Automation experience

Manufacturing engineering

Troubleshooting

Production support

Education

Electrical Engineering or related degree

Tools

Siemens PLCs

Allen-Bradley/Rockwell PLCs

Vision systems

MES systems

Robotics integration

Industrial networking

Job description

Insight Global is seeking a Senior Controls Engineer to join their team in Aiken, SC. This role supports a high-volume automotive manufacturing facility that produces molded carpet, foam, and insulation components used in vehicle interiors. The engineer will primarily support the molding and assembly operations, working with PLC-controlled automation systems that include robotics, vision inspection systems, VFDs, hydraulics, and manufacturing execution systems (MES). This position is approximately 40% production support and 60% project work, requiring someone who can quickly troubleshoot line-down situations while also driving automation improvements, controls modifications, capital projects, and equipment upgrades. The engineer will work closely with Maintenance, Production, Engineering, and another Senior Controls Engineer to improve uptime, process reliability, machine performance, and plant automation initiatives across a 24/7 manufacturing environment.

Must Have Skillsets

• 2+ years of hands-on controls, automation, manufacturing engineering, or PLC programming experience in a production environment
• Experience troubleshooting and modifying PLC programs in a manufacturing setting.
• Experience supporting automated equipment, production lines, machinery, or industrial controls systems.
• Ability to troubleshoot production issues involving PLCs, VFDs, motors, sensors, hydraulics, and machine controls.
• Ability to troubleshoot basic vision system issues and understand how vision systems interact with PLCs, robotics, and production equipment.

Plusses (Skillsets)

• Experience with Siemens or Allen-Bradley / Rockwell Automation PLCs.
• Experience with Keyence vision systems or other machine vision platforms.
• Experience with robotics, robotic integration, or automated assembly systems.
• Experience with MES, manufacturing data collection, industrial networking, or production reporting systems.
• Automotive manufacturing experience.
• Electrical Engineering, Controls Engineering, Mechatronics, or related degree (not required).

Compensation:

$65/hr to $80/hr.

Exact compensation may vary based on several factors, including skills, experience, and education.

Benefit packages for this role will start on the 31st day of employment and include medical, dental, and vision insurance, as well as HSA, FSA, and DCFSA account options, and 401k retirement account access with employer matching. Employees in this role are also entitled to paid sick leave and/or other paid time off as provided by applicable law