Senior Controls Engineer

Insight Global; Benson (NC); On-site; USD 105,000 - 145,000; Full time

Job summary

Insight Global is seeking a Sr. Controls Engineer (FAT/SAT & Commissioning) for a rapidly expanding manufacturing client in North Carolina. You will own the automation acceptance process across a major facility expansion, coordinating with OEMs, system integrators, and automation vendors.

The ideal candidate brings hands-on PLC programming, FAT/SAT leadership, and multi-vendor integration experience, with travel as required and a focus on production readiness.

Qualifications

• 7+ years of industrial automation and controls engineering experience.
• Strong hands-on PLC programming and commissioning experience with Siemens and Allen‑Bradley/Rockwell.
• Experience leading FAT, SAT, commissioning, and large‑scale equipment acceptance campaigns.
• Experience creating FAT/SAT protocols, punch lists, and acceptance documentation.
• Multi‑vendor integration experience with OEMs, system integrators, and automation suppliers.
• Strong knowledge of Ethernet/IP, Profinet, OPC UA, Modbus, and industrial networking.
• Experience with servos, VFDs, conveyors, robotic cells, motion control, and automated material handling systems.

Responsibilities

• Lead automation acceptance, FAT, SAT, and commissioning activities for a large manufacturing expansion.
• Develop standardized FAT/SAT protocols and manage program-wide punch lists.
• Review OEM controls architectures, schematics, PLC code, and HMI designs.
• Program, modify, troubleshoot, and commission Siemens and Rockwell PLCs.
• Coordinate integration of robotics, conveyors, AGVs, vision systems, servos, and material handling equipment.
• Validate controls, safety interlocks, alarms, networking, and system functionality.
• Partner with OEMs, Tier 2 vendors, and system integrators to ensure successful deployment.
• Support MES/SCADA connectivity and automation system performance.
• Serve as the senior escalation point for complex controls and commissioning issues.

Skills

Industrial automation

PLC programming

Commissioning

Troubleshooting

Tools

Siemens PLC

Allen-Bradley/Rockwell

HMI design

Ethernet/IP

Profinet

OPC UA

Modbus

Ignition

FactoryTalk

Wonderware

Job description

• BS/MS in Electrical Engineering, Automation Engineering, Mechatronics, or related field
• 7+ years of industrial automation and controls engineering experience
• Strong hands-on PLC programming and commissioning experience with Siemens and Allen‑Bradley/Rockwell
• Experience leading FAT, SAT, commissioning, and large‑scale equipment acceptance campaigns
• Experience creating FAT/SAT protocols, punch lists, and acceptance documentation
• Multi‑vendor integration experience with OEMs, system integrators, and automation suppliers
• Strong knowledge of Ethernet/IP, Profinet, OPC UA, Modbus, and industrial networking
• Experience with servos, VFDs, conveyors, robotic cells, motion control, and automated material handling systems

Ability to troubleshoot controls, networking, safety, and automation issues during commissioning

Nice to Have Skills & Experience

• SCADA/MES experience (Ignition, FactoryTalk, Wonderware)
• Experience in Defense, Aerospace, Automotive, Chemical, Metallurgical, or Greenfield manufacturing environments

Day-to-Day

• Lead automation acceptance, FAT, SAT, and commissioning activities for a large manufacturing expansion
• Develop standardized FAT/SAT protocols and manage program-wide punch lists
• Review OEM controls architectures, schematics, PLC code, and HMI designs
• Program, modify, troubleshoot, and commission Siemens and Rockwell PLCs
• Coordinate integration of robotics, conveyors, AGVs, vision systems, servos, and material handling equipment
• Validate controls, safety interlocks, alarms, networking, and system functionality
• Partner with OEMs, Tier 2 vendors, and system integrators to ensure successful deployment
• Support MES/SCADA connectivity and automation system performance
• Serve as the senior escalation point for complex controls and commissioning issues

Job Description

Insight Global is seeking a Sr. Controls Engineer (FAT/SAT & Commissioning) for a rapidly growing advanced manufacturing client in North Carolina. This engineer will own the automation acceptance process across a major manufacturing facility expansion, serving as the bridge between OEMs, system integrators, and automation vendors. The ideal candidate is a commissioning‑focused controls engineer who can both write and troubleshoot PLC code while driving FAT/SAT execution, equipment acceptance, and multi‑vendor integration efforts. This role is highly visible, highly technical, and ideal for someone who enjoys travel, commissioning, complex automation systems, and ensuring equipment is production‑ready before launch.