Senior Controls Engineer

CyberCoders; Grand Rapids (MI); On-site; USD 110,000 - 140,000; Full time

Benefits offered by this job

Medical benefits

Disability insurance

401(k) match

Education reimbursement

Paid time off

FSA

Job summary

CyberCoders is seeking a Senior Controls Engineer to lead design, implementation and commissioning of advanced industrial control systems for automated manufacturing equipment.

You will develop robust PLC/HMI and motion control solutions, integrate robotics and vision systems, and deliver reliable SCADA and factory-floor automation to improve safety, quality and productivity.

Qualifications

• Bachelors degree in Electrical, Controls, Mechatronics or related engineering discipline (or equivalent).
• 7+ years of controls engineering in industrial automation or manufacturing environments, with project leadership preferred.

Responsibilities

• Design control system architectures for machinery and lines, including PLC, HMI, motion and safety.
• Program and commission PLC/HMI systems (Rockwell, Siemens, Omron).
• Develop SCADA interfaces for real-time visibility and control.
• Integrate robots and cell controllers (Fanuc, ABB, Motoman) with Roboguide/RobotStudio.
• Implement machine vision for inspection and guidance tasks.
• Develop motion control and encoder-based sequencing for high-speed machinery.
• Create wiring diagrams and panel layouts using AutoCAD.
• Lead FAT/SAT, on-site troubleshooting and root-cause analysis.
• Ensure integration across drives, sensors, safety and networks (EtherNet/IP, Profinet, Modbus).
• Produce design packages, specs, test plans and SOPs; mentor junior staff.

Skills

7+ years experience

PLC programming

HMI programming

Motion control

Robotics integration

Vision systems

SCADA

AutoCAD/electrical CAD

Python/VBA scripting

AI tooling (ChatGPT)

Field commissioning

Industrial networks (EtherNet/IP, Profi

Education

Bachelor's degree in Electrical/Controls/Mechatronics

Tools

Rockwell ControlLogix/Studio5000

GuardLogix

Siemens PLCs

Omron PLCs

Rockwell FactoryTalk

Roboguide

RobotStudio

Cognex/Keyence vision

AutoCAD/electrical CAD

EtherNet/IP/Profinet/Modbus

Job description

Senior Controls Engineer

Position Overview

We are seeking a Senior Controls Engineer to lead the design, implementation and commissioning of advanced industrial control systems for automated manufacturing equipment. The role focuses on developing robust PLC/HMI and motion control solutions, integrating robotics and vision systems, and delivering reliable SCADA and factory-floor automation that improve safety, quality and productivity. The ideal candidate combines hands‑on technical expertise with project leadership and continuous improvement mindset.

Key Responsibilities

• Lead design and development of control system architectures for machinery and production lines, including PLC, HMI, motion control and safety systems.
• Program, test and commission PLC and HMI applications (Rockwell ControlLogix/GuardLogix, Studio5000, Siemens, Omron and equivalents).
• Design and implement SCADA solutions and operator interfaces (FactoryTalk, other SCADA platforms) to provide real-time visibility and control.
• Integrate industrial robots and cell controllers (Fanuc, ABB, Motoman) using tools such as Roboguide and RobotStudio; coordinate robot safety and part handling routines.
• Implement machine vision solutions and integrate with PLCs/robotics for inspection and guidance tasks.
• Develop motion control, servo and encoder‑based sequencing for high‑speed, synchronized machinery.
• Perform electrical and control system design tasks using AutoCAD and electrical CAD packages; create wiring diagrams, I/O lists and panel layouts.
• Lead commissioning, FAT/SAT activities, on‑site troubleshooting and root‑cause analysis to bring equipment to reliable production.
• Execute systems integration across drives, motors, sensors, vision, safety and SCADA; validate communication over EtherNet/IP, Profinet, Modbus and other industrial networks.
• Author and maintain technical documentation: design packages, functional specifications, test plans, commissioning reports and SOPs.
• Mentor and coach junior engineers and technicians; provide technical leadership across multidisciplinary project teams.
• Drive continuous improvement initiatives: optimize code, reduce cycle times, improve OEE and implement preventive maintenance strategies.
• Use scripting and automation tools (Python, VBA) and modern AI‑assisted tools (e.g., ChatGPT) to accelerate development, automate testing and improve diagnostics.
• Ensure designs and procedures comply with industry safety standards, local codes and internal quality systems.

Qualifications

• Bachelors degree in Electrical, Controls, Mechatronics or related engineering discipline (or equivalent experience).
• 7+ years of controls engineering experience in industrial automation, machine design or manufacturing environments; experience as lead controls engineer preferred.
• Strong PLC programming skills with Rockwell ControlLogix/Studio5000 and GuardLogix; experience with Siemens and Omron PLC platforms a plus.
• Hands‑on experience with Rockwell FactoryTalk, SCADA systems and HMI application development.
• Proven experience integrating industrial robots (Fanuc, ABB, Motoman) and using Roboguide and RobotStudio for offline programming and simulation.
• Practical knowledge of machine vision systems and integration with controls (Cognex, Keyence or similar).
• Expertise in motion control, servo drives, encoders and synchronized multi‑axis systems.
• Competence in electrical schematics, panel layouts and AutoCAD/electrical CAD tools.
• Strong troubleshooting, commissioning and field support experience with FAT/SAT and site acceptance testing.
• Experience with scripting and automation (Python, VBA); comfortable leveraging AI tools like ChatGPT to improve productivity.
• Willingness to travel to customer sites for commissioning and support; valid drivers license.

Benefits

• - Medical, Dental, Vision
• - Short and Long Term Disability
• - 401(k) with Company Match
• - Education reimbursement
• - PTO and Holidays
• - FSA