Senior Controls Engineer

Synergy Staffing; Hartsville (SC); On-site; USD 110,000 - 140,000; Full time

Job summary

Synergy Staffing is seeking a Senior Controls Engineer to lead the design, development, and implementation of advanced automation and controls solutions for a growing machinery manufacturer in South Carolina.

You will own the full lifecycle—from concept and electrical design to programming, panel fabrication, commissioning, and ongoing support—while collaborating with engineering, operations, maintenance, vendors, and OEM partners.

Qualifications

• Bachelor's degree in Electrical Engineering or Controls Engineering.
• 8–10+ years of experience in controls and automation design.
• Experience with automated manufacturing machinery and equipment.
• Advanced PLC programming, preferably Rockwell/Studio 5000.
• Experience developing and troubleshooting HMI applications.
• Knowledge of electrical controls, control panels, automation hardware.
• Strong safety and machine controls knowledge.

Responsibilities

• Lead electrical and controls design of custom automation and manufacturing equipment.
• Program, test, and troubleshoot Allen-Bradley/Rockwell PLC systems using Studio 5000.
• Develop user-friendly HMI applications and alarms.
• Support control-panel fabrication, equipment assembly, shop testing, installation, and commissioning.
• Troubleshoot complex electrical, controls, and automation issues.
• Develop automation solutions prioritizing safety, reliability, maintainability, and consistency.
• Establish and maintain engineering standards for controls and automation projects.
• Manage revisions and change-control processes for drawings and code.
• Lead technical design discussions to identify practical automation solutions.
• Manage automation projects from concept through completion on schedule and budget.
• Coordinate internal resources, technicians, contractors, suppliers, and OEM partners.
• Develop scopes of work and technical requirements for new equipment.
• Support automated data collection and continuous improvement.
• Prepare and present capital-project proposals.
• Partner with manufacturing, operations, and maintenance teams.

Skills

Manufacturing automation

Electrical controls design

PLC/HMI programming

Automated machinery

Project leadership

Team collaboration

Education

Bachelor's degree in Electrical Engineering or Controls Engineering

Tools

Studio 5000

Rockwell Automation

EPLAN

HMIs

Panel fabrication software

Job description

We are seeking an experienced Senior Controls Engineer to take a lead role in the development and implementation of advanced automation and controls solutions within a growing machinery manufacturing operation.

This position will be heavily involved throughout the entire automation lifecycle — from initial concept and electrical design through programming, panel fabrication, integration, commissioning, installation, and ongoing technical support.

The ideal candidate brings a strong background in manufacturing automation, electrical controls design, PLC/HMI programming, and automated machinery, along with the ability to lead projects and collaborate with engineering, operations, maintenance, vendors, and other technical resources.

What You'll Be Doing

• Lead the electrical and controls design of custom automation and manufacturing equipment.
• Program, test, and troubleshoot Allen-Bradley/Rockwell PLC systems using Studio 5000.
• Develop user-friendly HMI applications and incorporate alarms, messaging, and equipment-status functionality.
• Support and guide technicians during control-panel fabrication, equipment assembly, shop testing, installation, and commissioning.
• Troubleshoot complex electrical, controls, and automation issues on manufacturing equipment.
• Develop automation solutions that prioritize safety, reliability, maintainability, and consistency.
• Establish and maintain engineering standards for controls and automation projects.
• Manage revisions and change-control processes involving electrical drawings, source code, and other technical documentation.
• Participate in and lead technical design discussions to identify practical automation solutions for complex manufacturing challenges.
• Manage automation projects from concept through completion, ensuring projects remain on schedule and within budget.
• Coordinate internal engineering resources, technicians, contractors, suppliers, and OEM partners.
• Develop scopes of work and technical requirements for new equipment and automation projects.
• Support automated data collection, equipment reliability tracking, and continuous improvement initiatives.
• Prepare and present capital-project proposals to plant and organizational leadership.
• Partner closely with manufacturing, operations, and maintenance teams to ensure automated equipment is properly implemented, operated, and supported.
• Provide technical direction to designers, drafters, technicians, and other resources assigned to automation projects.
• Travel to manufacturing locations and vendor facilities as necessary to support project execution.

What We're Looking For

• Bachelor's degree in Electrical Engineering, Controls Engineering, or a related technical discipline; equivalent relevant experience may also be considered.
• Approximately 8–10+ years of experience in controls and automation design.
• Strong experience designing controls for automated manufacturing machinery and equipment.
• Advanced PLC programming experience, preferably with Rockwell/Allen-Bradley Studio 5000.
• Experience developing and troubleshooting HMI applications.
• Strong knowledge of electrical controls, control panels, automation hardware, and industrial equipment.
• Experience with electrical design software; EPLAN experience is strongly preferred.
• Experience supporting control-panel fabrication and equipment integration.
• Strong background in equipment commissioning, testing, installation, and advanced troubleshooting.
• Understanding of applicable machine and controls safety requirements.
• Ability to lead projects and coordinate internal and external technical resources.
• Strong analytical and problem-solving skills with the ability to diagnose complex equipment and controls issues.
• Excellent communication skills and the ability to collaborate across engineering, manufacturing, operations, maintenance, suppliers, and leadership.
• Ability to perform effectively in a fast-paced manufacturing and project environment.

Preferred Experience

Experience with any of the following would be particularly valuable:

• Allen-Bradley / Rockwell Automation
• Maple Systems HMIs
• Ignition or similar SCADA platforms
• Control-panel design and fabrication
• Automated machinery design and integration
• OEM or machine-builder environments
• Manufacturing equipment commissioning

This is an excellent opportunity for a senior-level controls professional who enjoys being involved in the full lifecycle of automation projects and wants to play a key role in developing innovative manufacturing equipment and controls solutions.