Senior controls engineer

Cognify Global; Sterling (MA); On-site; USD 120,000 - 170,000; Full time

Job summary

Cognify Global is seeking an experienced Senior Controls Engineer to lead automation projects from design through startup. You will architect control systems, code PLC/HMI, and coordinate with mechanical, software, and operations teams to deliver robust solutions.

The role emphasizes hands-on engineering, mentoring junior staff, rigorous documentation, and adherence to safety standards. You will drive system integration, commissioning, and continuous improvement across manufacturing environments.

Qualifications

• Bachelor’s degree in electrical engineering, computer science, controls engineering, or related field.
• 8+ years of experience in controls, automation, or electrical engineering.
• Hands‑on PLC and HMI programming experience.
• Experience with SCADA/visualization and industrial data systems.
• Familiarity with servo, motion, machine vision, and sensors.
• Strong communication and mentoring skills.

Responsibilities

• Lead complex automation projects from concept through startup.
• Design control architectures and electrical schematics.
• Develop and maintain programming standards and templates.
• Integrate automation equipment with manufacturing systems.
• Provide technical guidance and training to teams and customers.
• Ensure compliance with codes and safety requirements.

Skills

Leadership

Mentoring

Communication

Team collaboration

Education

Bachelor’s degree in electrical engineering, controls engineering, or related field

Tools

PLC programming

HMI programming

SCADA/Visualization

Machine vision

Motion control

Electrical schematics

Job description

• Technical Leadership: Lead complex automation and controls projects from initial design through installation and startup. Make key technical decisions, establish the overall engineering approach, and provide guidance to engineers and technical staff throughout the project lifecycle.
• Controls Programming: Design, develop, and support PLC, HMI, safety, motion, and machine vision applications using a variety of industrial automation platforms. Develop SCADA and plant visualization solutions as required.
• Controls Architecture & Electrical Design: Define control system architectures and develop electrical schematics, panel layouts, and related design documentation. Help establish consistent electrical and controls design practices across projects.
• Engineering Standards: Create and maintain programming standards, reusable software components, design guidelines, and documentation templates to improve engineering quality and efficiency.
• System Integration: Integrate automation equipment with manufacturing systems and processes while coordinating with mechanical, electrical, software, and operations teams.
• Startup & Troubleshooting: Lead equipment startup and commissioning activities, diagnose complex controls and integration issues, and optimize systems for reliability, performance, and maintainability.
• Mentoring & Support: Provide technical mentorship to less-experienced engineers and technicians. Conduct design and code reviews and provide technical training and support to internal teams and customers.
• Project Management: Manage technical scope, schedules, budgets, suppliers, and project changes to support successful delivery.
• Safety & Compliance: Ensure control systems and electrical designs comply with applicable codes, industry standards, and workplace safety requirements.

Qualifications

• Education: Bachelor’s degree in electrical engineering, computer science, controls engineering, or a related technical discipline.
• Experience: Approximately 8 or more years of experience in controls, automation, or electrical engineering, preferably supporting industrial equipment, manufacturing systems, or custom machinery.
• Automation Expertise: Strong hands‑on experience programming and configuring industrial PLC and HMI systems. Familiarity with several major controls platforms is preferred.
• SCADA & Visualization: Experience developing industrial visualization, SCADA, or manufacturing data systems is highly desirable.
• Advanced Controls: Experience with servo and motion systems, machine vision, industrial sensors, instrumentation, and data acquisition.
• Electrical Documentation: Strong experience creating and maintaining electrical drawings, panel documentation, bills of materials, and other technical project documentation.
• Supplier Coordination: Experience sourcing custom components, reviewing supplier quotations, coordinating fabrication or machining work, and managing vendor relationships.
• Project Delivery: Demonstrated ability to independently manage controls projects from concept through commissioning while meeting schedule and budget requirements.
• Adaptability: Comfortable working in a hands‑on engineering environment where responsibilities may span design, programming, troubleshooting, procurement, customer support, and project coordination.
• Communication: Strong written and verbal communication skills with the ability to work effectively with engineers, technicians, customers, vendors, and non‑technical stakeholders.