Senior Controls Engineer

DSJ Global; Andover (MA); On-site; USD 100,000 - 140,000; Full time

Job summary

A leading company in Boston is seeking a Senior Controls Engineer to join their automation engineering team. The role involves designing and optimizing control systems for production equipment in various high-tech industries. The successful candidate will be responsible for ensuring compliance with safety standards while collaborating with technical teams on complex automation projects.

Qualifications

• Investigate and repair electrical control systems at component level.
• Modify existing systems for performance improvement.
• Develop user manuals and design network documentation.

Responsibilities

• Design and develop control systems and ensure compliance with safety standards.
• Lead cross-functional teams in automation projects.
• Support installation and troubleshooting of automation devices.

Skills

Control systems design

Automated machinery support

Troubleshooting

Electrical standards compliance

Panel wiring

Education

Bachelor's degree in Electrical or Computer Engineering

Tools

CAD tools

PLC programming

HMI systems

Pneumatics

VFDs

Job description

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Base pay range

$100,000.00/yr - $140,000.00/yr

Direct message the job poster from DSJ Global

Head of DSJ Global Boston | E2E Supply Chain, Manufacturing Operations, Engineering, & Logistics

Overview:

We are seeking a highly skilled Senior Controls Engineer to join a dynamic automation engineering team. This role involves designing, implementing, and optimizing control systems for both new and existing production equipment. The ideal candidate will contribute to the development of advanced automation solutions used across a variety of high-tech industries including industrial manufacturing, AI, aerospace, defense, and automotive.

Key Responsibilities:

Electrical & Controls Engineering:

• Design and develop control systems, including schematics, component selection, and network configurations.
• Build and wire control panels, ensuring compliance with relevant electrical standards.
• Modify and enhance existing production systems to improve performance and reliability.
• Lead or support cross-functional teams in the development of custom automation machinery.
• Ensure projects meet scope, quality, schedule, and budget targets.
• Balance immediate operational needs with long-term engineering initiatives.
• Provide expert-level support for automation systems across manufacturing and engineering departments.
• Assist in the design and operation of control systems and automation processes.
• Collaborate with technical teams to resolve communication issues between equipment and enterprise networks.
• Support installation and troubleshooting of IP-based devices such as code scanners.

Technical Support:

• Diagnose and repair electrical control systems down to the component level.
• Provide hands-on support for pneumatics, servos, VFDs, relays, HMIs, and integrated automation systems.
• Create detailed electrical schematics, panel layouts, and BOMs using CAD tools.
• Develop user manuals, programming diagrams, and network documentation for technical teams.
• Ensure all designs and implementations adhere to NFPA, OSHA, and internal safety standards.
• Contribute to capital equipment projects, including integration of software and hardware, vendor coordination, and system commissioning.
• Develop and maintain PLC programs using ladder logic.
• Implement cost-effective control solutions and maintain software backups.
• Troubleshoot and debug PLC and HMI systems.
• Work with machine vision technologies such as Cognex Insight, VisionPro, and VIDI for inspection and automation tasks.
• Stay current with advancements in sensors, vision systems, and automation technologies.
• Evaluate and recommend new components and technologies for system improvements.

Qualifications:

• Bachelor's degree in Electrical or Computer Engineering.

Seniority level

• Seniority level

  Mid-Senior level

Employment type

• Employment type

  Full-time

Job function

• Industries

  Appliances, Electrical, and Electronics Manufacturing

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