Senior Controls Engineer

IMG-NA; Michigan; On-site; USD 110,000 - 140,000; Full time

Job summary

IMG-NA is seeking a Senior Controls Engineer in Michigan to own and advance control systems for large-scale machinery. You will design, program, and maintain PLC and HMI solutions, lead project commissioning, and ensure safety standards across multiple teams.

You will mentor engineers, coordinate with contractors, and generate thorough documentation. Strong expertise in Allen-Bradley, Siemens platforms, and safety protocols is required to drive continuous improvements and reliable operation.

Qualifications

• Bachelor's degree in Controls Engineering or equivalent work experience.
• 8+ years of automation experience in systems integration roles.
• Strong experience with Allen-Bradley Studio 5000 and FactoryTalk View.
• Experience commissioning machines, IO checkout, Ethernet/IP setup, and safety testing.
• Experience with servo drives and VFDs.
• Knowledge of machine safety design and safety PLCs.

Responsibilities

• Develop, program, and maintain PLC and HMI control systems for machinery and projects.
• Lead large-scale project commissioning to ensure systems meet performance standards.
• Drive safety compliance in controls design and code per standards.
• Coordinate with internal and external teams to meet technical requirements.
• Mentor junior engineers and manage controls contractors on projects.
• Create and maintain detailed technical documentation including schematics and user manuals.
• Provide troubleshooting and support to minimize downtime on existing machines.
• Identify improvements to enhance performance and expand code libraries.

Skills

PLC programming

HMI development

Industrial control systems

Leadership

Troubleshooting

Communication

Detail-oriented

Education

Bachelor's degree in Controls Engineering

Tools

Allen-Bradley Studio 5000

FactoryTalk View

Siemens TIA Portal

WinCC

Job description

The Senior Controls Engineer plays a critical role in the development and implementation of control systems for our large-scale projects and machinery. You will take ownership of complex aspects of our codebase, oversee project commissioning, and manage coordination with external teams. Mentoring junior engineers and leading various aspects of controls and robotics within your expertise will be integral to your responsibilities. Your contributions will include designing and implementing control systems, utilizing PLCs and HMIs, and ensuring the technical success of our projects.

Key Responsibilities:

• Develop and Maintain Control Systems: Design, program, and maintain PLC and HMI systems for various machinery and projects.
• Project Commissioning: Lead the commissioning of large-scale projects, ensuring systems are fully operational and meet performance standards.
• Controls Safety: Lead the controls efforts to produce compliant and safe machinery and code, following all applicable safety standards.
• Technical Coordination: Coordinate with internal and external teams to ensure technical requirements are met and projects are delivered on time.
• Mentorship and Leadership: Mentor junior engineers, providing guidance and sharing expertise in controls and robotics. Manage controls contractors’ day-to-day work on assigned projects.
• Technical Documentation: Create and maintain detailed documentation, including schematics, code, and user manuals.
• Troubleshooting and Support: Provide technical support and troubleshoot issues with existing machines to ensure minimal downtime.
• Continuous Improvement: Identify and implement improvements to machines to enhance performance and reliability. Expand existing code libraries with new features and improvements.

Attributes of a Successful Senior Controls Engineer:

• Technical Expertise: Deep knowledge and experience with PLCs, HMIs, and industrial control systems.
• Problem Solver: Strong troubleshooting skills and the ability to solve complex technical issues.
• Leadership Skills: Ability to lead and mentor a team of engineers, fostering a collaborative and innovative environment.
• Effective Communicator: Clear and concise communication skills, both oral and written, to convey technical information effectively.
• Detail-Oriented: Strong attention to detail, ensuring high-quality work and adherence to technical standards.

Education/Skills/Required Experience:

• B.S. degree in Controls Engineering OR equivalent education or work experience.
• 8+ years of experience working in the automation field in a new systems integration role.
• Strong experience in working with Allen-Bradley Studio 5000 and Factory Talk View.
• Experience commissioning machines, including I/O Checkout, Ethernet/IP device setup, and machine safety testing.
• Experience in commissioning various brands of servo drives and VFDs.
• Experience and knowledge of machine safety design and requirements, including robot safety, operator safety, programming various safety PLCs and relays, and area scanners.
• Ability to read and markup electrical prints.
• Hands-on experience with electrical wiring, pneumatics, and troubleshooting.

Behavioral Requirements:

• Has high standards of work ethics.
• Takes responsibility for actions, results, and mistakes.
• Is thorough, accurate, and reliable when performing and completing job tasks.
• Demonstrates honesty and integrity in all aspects of work.
• Works with a sense of urgency to meet the needs of customers.
• Looks for good in others, works collaboratively with others, shares information and knowledge.
• Willing and able to travel to customer sites in North America, up to 35%

Preferred Experience:

• Familiarity with major robot platforms, such as FANUC, KUKA, and ABB.
• Programming experience with Siemens TIA Portal and WinCC.