Senior Controls Engineer

APEX Controls; Hudsonville (MI); On-site; USD 80,000 - 110,000; Full time

Job summary

APEX Controls in Hudsonville is seeking a Senior Controls Engineer to lead the development and optimization of automated control systems for manufacturing processes. You will drive improvements in reliability and efficiency while ensuring compliance with regulations.

The role requires strong experience in DCS, PLC programming, and project leadership. You will collaborate cross-functionally and mentor junior engineers, making this an excellent opportunity for career growth.

Qualifications

• Five plus years of controls systems automation work experience may be acceptable.
• Familiar with National Electric Code and other common electrical standards.
• Experience in a regulated industry (e.g., pharmaceuticals, chemicals).

Responsibilities

• Lead the design and configuration of control systems.
• Implement process optimization strategies.
• Mentor and train junior engineers.

Skills

Control system design and maintenance

Process optimization

Proficiency in DCS/PLC programming

Strong problem-solving skills

Communication skills

Education

BS degree in engineering or related discipline

Tools

2-D CAD software

Rockwell and Siemens systems

Job description

Job Description

Apex Controls is seeking a highly skilled and experienced Senior Controls Engineer to join our dynamic team. The ideal candidate will lead the development, implementation, and optimization of automated control systems for customers' manufacturing processes. You will collaborate closely with multidisciplinary teams to ensure efficient, reliable, and safe operations. Your expertise will help drive improvements in productivity, quality, and process controls, while ensuring compliance with industry regulations.

This role is a full‑time salaried‑exempt role; the salary ranges listed below include total rewards such as base salary, premium pay, bonus & benefits.

Responsibilities

• Lead the design, configuration, and maintenance of control systems (PLC, SCADA, HMI) across customers facility.
• Analyze, troubleshoot, and resolve issues related to control systems, instrumentation, and automation.
• Implement process optimization strategies to improve efficiency, reduce downtime, and minimize waste.
• Optimize control system process loops.
• Collaborate with customers to ensure smooth integration of control systems.
• Develop and manage process control documentation, including control system functional specifications documents, P&IDs, and system architecture diagrams.
• Provide technical leadership for capital projects, including scope development, commissioning, and validation.
• Lead control system upgrades, migrations, and expansions to support future process enhancements.
• Mentor and train junior engineers and technical staff in process control best practices.
• Ensure compliance with safety, environmental, and regulatory requirements.
• Understand and comply with internal standards, customer‑specific standards recognized national/international standards and safety standards.
• Work with both Apex and customer staff to evaluate future projects.
• Work with internal and external electricians and electrical technicians in the review of control system construction and wiring, including troubleshooting assistance of both Apex Controls’ design and interfaces to systems provided by others.
• Provide timely and accurate feedback regarding project status.
• Participate in, and lead, training of customers, both technical and non‑technical.
• Willing to participate/lead internal training activities.
• Actively share knowledge with peers.
• Willing and able to travel when needed.
• Always act with honesty and integrity.

Requirements

• BS degree in engineering or related discipline is preferred. Five plus years of controls systems automation work experience may be acceptable.
• Proficient with 2‑D CAD software.
• Proficiency in DCS, Plant PAX, PLC, SCADA, HMI programming and troubleshooting (e.g., Rockwell, Siemens).
• Experience in process optimization and advanced control strategies (e.g., PID tuning).
• Familiar with National Electric Code and other common electrical standards, including safety standards.
• Experience with control system hardware and software.
• Proven ability to lead projects and cross‑functional teams.
• Highly organized and able to multitask
• Strong problem‑solving, analytical, and critical‑thinking skills.
• Strong communicator, both internally and with customers or suppliers
• Experience in a regulated industry (e.g., pharmaceuticals, chemicals, oil & gas, food & beverage, wastewater).
• Certification in process control systems (e.g., ISA, TUV) is a plus but not required.