Senior Controls Engineer - Factory Acceptance Testing (FAT) & Commissioning

Greene Resources; North Carolina; On-site; USD 120,000 - 160,000; Full time

Job summary

Greene Resources is seeking a Senior Controls Engineer focused on FAT, SAT, and commissioning for a major manufacturing expansion in North Carolina. You will lead hands-on PLC/HMI development, testing, and acceptance activities across Siemens and Allen-Bradley systems, while coordinating with OEMs and internal teams.

Ideal candidates have 7+ years in industrial automation, strong troubleshooting skills, and experience managing large acceptance campaigns, with exposure to robotics, SCADA/MES, and

Qualifications

• Bachelor’s or Master’s degree in Electrical Engineering, Automation Engineering, Mechatronics, or related field.
• 7+ years of direct industrial automation and controls engineering experience.
• Hands-on experience programming, troubleshooting, and commissioning Siemens and Allen-Bradley/Rockwell PLCs and HMIs.
• Experience managing multi-vendor equipment acceptance campaigns, FAT/SAT activities, punch lists, and change control.

Responsibilities

• Lead hands-on programming, debugging, testing, and commissioning of Siemens and Allen-Bradley/Rockwell PLCs and HMIs for new and existing automation equipment.
• Develop, modify, and maintain PLC code structures, HMI screens, safety circuits, and network configurations.
• Own the FAT/SAT campaign, including developing standardized acceptance protocols for PLC logic, HMI functionality, alarms, interlocks, networking, and security.

Skills

leadership

hands-on programming

troubleshooting

industrial networking

project coordination

Education

Bachelor’s or Master’s degree in Electrical Engineering or related field

Tools

Siemens PLCs

Allen-Bradley/Rockwell PLCs

HMI programming

FAT/SAT protocols

CSV validation

Job description

As the Senior Controls Engineer Factory Acceptance Testing (FAT) & Commissioning, you will lead automation acceptance, testing, and commissioning activities for a major 1 million-square-foot manufacturing facility expansion. You will own the automation acceptance process across a large OEM equipment campaign, including developing standardized FAT/SAT protocols, managing the program-wide punch list, and writing, modifying, debugging, and commissioning PLC and HMI code. This is a high-impact, hands-on role requiring deep industrial automation expertise and the ability to work across engineering, quality, manufacturing, vendors, and OEM partners.

The position will initially be based in Durham, NC and is expected to transition to Benson, NC upon completion of the new facility. The schedule is8:00am – 5:00pm with flexibility required during FAT, commissioning, and production support activities.

Experience and Education Requirements:

• Bachelor’s or Master’s degree in Electrical Engineering, Automation Engineering, Mechatronics, or a related field.
• 7+ years of direct industrial automation and controls engineering experience.
• Strong hands-on experience programming, troubleshooting, and commissioning Siemens and Allen-Bradley/Rockwell PLCs and HMIs.
• Demonstrated experience managing multi-vendor equipment acceptance campaigns, FAT/SAT activities, punch lists, and change control.
• Strong understanding of servos, VFDs, high-speed conveyors, robotic cells, and automated material handling systems.
• Experience with industrial communication protocols including EtherNet/IP, PROFINET, EtherCAT, OPC UA, Modbus, and serial communications.
• Must be a U.S. Person due to required access to U.S. export-controlled information or facilities.

Key Responsibilities

• Lead hands-on programming, debugging, testing, and commissioning of Siemens and Allen-Bradley/Rockwell PLCs and HMIs for new and existing automation equipment.
• Develop, modify, and maintain PLC code structures, HMI screens, safety circuits, device mapping, and network configurations.
• Lead equipment design reviews and convert findings into detailed technical requirements and deliverables for OEM vendors.
• Review vendor electrical schematics, controls architectures, PLC logic, and HMI programs.
• Own the FAT/SAT campaign, including developing standardized acceptance protocols for PLC logic, HMI functionality, alarms, interlocks, networking, and security.
• Manage the program-wide punch list, coordinate witness assignments, track punch-item resolution, and maintain acceptance evidence.
• Maintain as-tested PLC code, configuration baselines, system backups, punch-closure documentation, and commissioning records.
• Partner with Quality to integrate automation protocols into the validation framework and ensure alignment with quality and manufacturing requirements.
• Coordinate with Manufacturing Engineering to ensure automation activities align with the master project schedule and process acceptance criteria.
• Lead the integration and commissioning of robotics, vision systems, AGVs, conveyors, servos, VFDs, and other motion-control systems.
• Configure and maintain communication between PLCs/HMIs and higher-level MES and SCADA platforms.
• Develop and troubleshoot SCADA tags, transactions, alarms, and data acquisition functionality.
• Serve as a senior escalation point for complex automation issues involving industrial networks, motion systems, instrumentation, and communication protocols.

Skill Requirements:

• Siemens and Allen-Bradley/Rockwell PLC programming and commissioning
• HMI programming and development
• FAT/SAT protocol development and execution
• Computer System Validation (CSV) and validation documentation
• PLC code architecture and troubleshooting
• Industrial networking and communications
• SCADA/MES integration and troubleshooting
• Servo motors, VFDs, conveyors, and motion control
• Robotics and machine vision integration
• Electrical schematics and controls architecture
• Automation safety circuits and interlocks
• Controls risk assessments and PFMEA support
• Industrial network topology and device mapping
• Technical documentation and change control
• PLC code architecture and as-tested code baselines
• HMI screens and configurations
• Vision inspection programs
• MES/SCADA transaction lists
• Network IP lists and network topology documentation
• Password inventories and system backups
• Configuration backups and acceptance evidence packages
• Interlock and guarding logic
• Safety-rated PFMEA inputs
• Controls layouts and sequence diagrams
• Automation simulations
• Electrical schematics and pneumatic drawings
• Controls panel layouts
• FAT/SAT protocols
• Program-wide punch lists
• I/O checkout records
• Commissioning and handover packages

Preferred Qualifications

• Previous experience as a commissioning-focused Controls Engineer with a system integrator or machine OEM, ideally with experience both developing machine code and accepting or reviewing code developed by others.
• Experience with multi-axis robotic systems such as FANUC, KUKA, or ABB.
• Experience with machine vision platforms such as Cognex or Keyence.
• Experience working in heavy industrial, greenfield, chemical, or metallurgical manufacturing environments.
• SCADA development experience using Ignition, FactoryTalk, Wonderware, or similar platforms.
• Familiarity with Python, C++, or other high-level programming languages used for automation or data analytics.
• Experience working in regulated industries such as defense, aerospace, or automotive.
• Familiarity with GAMP 5 and/or Computer System Validation (CSV) practices.

Physical and Environmental Requirements

This position requires regular presence on the production floor and the ability to navigate throughout the manufacturing facility. Candidates must be able to climb stairs, stand and walk for extended periods, and work in environments that may be hot, humid, or noisy.

The role requires the use of appropriate personal protective equipment, including respirators when necessary, and adherence to all applicable safety policies, procedures, and regulatory requirements. Employees must be able to complete required fit testing, wear designated PPE for the duration of assigned tasks, and safely respond to changing conditions within the production environment.

Responsibilities and duties listed above are not exhaustive and may change based on the needs of the business.

• Opportunity to play a key role in a major 1 million-square-foot manufacturing facility expansion.
• High-visibility, high-ownership engineering position with significant influence over automation standards and equipment acceptance.
• Hands-on involvement with advanced automation technologies, robotics, vision systems, AGVs, SCADA/MES, and industrial controls.
• Domestic and international exposure through OEM testing and commissioning campaigns.
• Specific compensation and benefits information to be provided by the employer.