Senior Controls Engineer

Lvi-Associates; Springfield (NJ); On-site; USD 130,000 - 170,000; Full time

Job summary

Lvi-Associates in Springfield, NJ is seeking a Senior Controls Engineer to anchor its engineering team. You will lead projects from concept to commissioning, shape system architecture, and coach junior engineers on complex control systems.

You’ll work hands-on across PLC, HMI, motion control, robotics, and vision applications, collaborating with customers and internal teams to deliver reliable, scalable manufacturing solutions in a lean environment.

Qualifications

• Bachelor’s degree in electrical, mechanical, computer science, or related technical discipline.
• 8+ years in controls engineering with independent project ownership.
• Hands-on PLC programming and configuration; Rockwell preferred.
• Robotics, motion control, vision, and data acquisition expertise.
• Experience with BOMs and electrical drawing packages.
• Strong communication and leadership capabilities.

Responsibilities

• Act as lead engineer on complex, multi-disciplinary builds, guiding architecture decisions.
• Design and implement PLC, HMI, motion control, robotics, and vision applications.
• Create engineering standards, reusable code libraries, and templates.
• Oversee system integration, coordinating mechanical, electrical, and software workstreams.
• Lead on-site commissioning, troubleshooting, and performance optimization.
• Mentor junior engineers and conduct design/code reviews.
• Manage project schedules, budgets, and vendor relationships.
• Ensure compliance with safety standards including UL 508A.

Skills

Technical leadership

PLC programming

Team mentoring

Communication

Project delivery

Lean / small-shop mindset

Problem solving

System integration

Education

Bachelor's degree in Electrical Engineering

Bachelor's degree in Mechanical Engineering

Bachelor's degree in Computer Science

Tools

Allen-Bradley

Siemens

Beckhoff

Vision systems

Robotics

Job description

Salary: USD130000 - USD170000 per annum

Springfield, NJ

A growing automation systems integrator specialising in custom machine building and full systems integration is looking for a Senior Controls Engineer to anchor its engineering team in Springfield, NJ. This is a hands‑on technical leadership position suited to an experienced professional who can take complex projects from concept to completion — shaping system architecture, leading the programming effort, and running commissioning, all while coaching less‑experienced engineers and acting as a go‑to technical advisor for customers. The successful candidate will bring deep practical expertise, sound decision‑making when requirements are unclear, and the confidence to lead through influence within a lean, fast‑paced team.

Key Responsibilities

• Technical Leadership: Act as lead engineer on complex, multi‑disciplinary builds — owning key architecture decisions, setting the technical direction, and guiding engineers and technicians from initial concept through to commissioning.
• Advanced Programming: Design and build PLC, HMI, motion control, robotics, and vision applications across leading platforms such as Allen‑Bradley, Siemens, FANUC, UR, Cognex, Keyence, and Beckhoff.
• Standards & Best Practice: Create and maintain engineering standards, reusable code libraries, and documentation templates that lift quality and consistency across the project portfolio.
• System Integration: Oversee the integration of control systems into existing manufacturing lines, coordinating mechanical, electrical, and software workstreams to deliver efficient, reliable, and maintainable solutions.
• Commissioning & Troubleshooting: Lead on‑site start‑up, system analysis, and advanced fault‑finding, resolving the most difficult integration and performance challenges to keep equipment running at its best.
• Mentorship & Support: Guide junior and mid‑level engineers, run design and code reviews, and provide expert support and training to internal teams, technicians and customers.
• Project Execution: Manage project schedules, budgets, and vendor relationships, controlling scope and change orders to deliver on time and on budget.
• Compliance & Safety: Ensure every project meets regulatory requirements and follows strict safety practices, including applicable UL 508A and industrial electrical safety standards.

Qualifications

• Education: A bachelor's degree in electrical engineering, mechanical engineering, computer science, or a related technical discipline is required.
• Experience: At least 8 years in controls engineering, ideally within industrial, manufacturing, systems integration, or custom machine‑building settings, with a proven record of running projects independently from concept to commissioning.
• Technical Proficiency: Extensive, hands‑on PLC programming and configuration skills. Rockwell platform experience is strongly preferred, with Siemens and/or Beckhoff proficiency also valued. A solid grounding in robotics, motion control, vision systems, sensor integration, and data acquisition is essential.
• BOM & Documentation: Expert‑level handling of structured BOMs and full electrical drawing packages across the complete project lifecycle.
• Delivery Track Record: Consistent success delivering on time and on budget in a project‑based or job‑shop setting, including ownership of change‑order processes.
• Small‑Shop Mindset: Comfortable in a lean, self‑directed environment — happy to wear multiple hats and take full ownership of outcomes. Previous experience with an integrator or custom machine builder is a strong advantage.
• Communication: Clear, direct communicator with internal teams, customers, and vendors, able to translate complex technical detail for different audiences.

What's on Offer

• Competitive salary with annual bonus potential and a clear path toward career growth and technical leadership.
• A collaborative, low‑bureaucracy culture where individual decisions carry real weight.
• Exposure to a wide range of industries and machine types — no two projects are alike.
• A team that takes pride in craftsmanship, accountability, and continuous improvement.

Core Values

• Champion the Customer: Build genuine partnerships, do the right thing, and win as a team.
• Own It: Take accountability, work the problem, and drive results.
• Deliver Excellence: Take pride in the work, bring expertise, and sweat the details.
• Spark Innovation: Stay curious, embrace challenges, and keep growing.
• Stronger Together: Respect, support, and look out for one another.