Senior Controls Engineer: FAT/SAT & Commissioning Lead

Insight Global; Benson (NC); On-site; USD 105,000 - 145,000; Full time

Job summary

Insight Global is seeking a Sr. Controls Engineer (FAT/SAT & Commissioning) for a rapidly expanding manufacturing client in North Carolina. You will own the automation acceptance process across a major facility expansion, coordinating with OEMs, system integrators, and automation vendors.

The ideal candidate brings hands-on PLC programming, FAT/SAT leadership, and multi-vendor integration experience, with travel as required and a focus on production readiness.

Qualifications

• 7+ years of industrial automation and controls engineering experience.
• Strong hands-on PLC programming and commissioning experience with Siemens and Allen‑Bradley/Rockwell.
• Experience leading FAT, SAT, commissioning, and large‑scale equipment acceptance campaigns.
• Experience creating FAT/SAT protocols, punch lists, and acceptance documentation.
• Multi‑vendor integration experience with OEMs, system integrators, and automation suppliers.
• Strong knowledge of Ethernet/IP, Profinet, OPC UA, Modbus, and industrial networking.
• Experience with servos, VFDs, conveyors, robotic cells, motion control, and automated material handling systems.

Responsibilities

• Lead automation acceptance, FAT, SAT, and commissioning activities for a large manufacturing expansion.
• Develop standardized FAT/SAT protocols and manage program-wide punch lists.
• Review OEM controls architectures, schematics, PLC code, and HMI designs.
• Program, modify, troubleshoot, and commission Siemens and Rockwell PLCs.
• Coordinate integration of robotics, conveyors, AGVs, vision systems, servos, and material handling equipment.
• Validate controls, safety interlocks, alarms, networking, and system functionality.
• Partner with OEMs, Tier 2 vendors, and system integrators to ensure successful deployment.
• Support MES/SCADA connectivity and automation system performance.
• Serve as the senior escalation point for complex controls and commissioning issues.

Skills

Industrial automation

PLC programming

Commissioning

Troubleshooting

Tools

Siemens PLC

Allen-Bradley/Rockwell

HMI design

Ethernet/IP

Profinet

OPC UA

Modbus

Ignition

FactoryTalk

Wonderware

Job description

Insight Global is seeking a Sr. Controls Engineer (FAT/SAT & Commissioning) for a rapidly expanding manufacturing client in North Carolina. You will own the automation acceptance process across a major facility expansion, coordinating with OEMs, system integrators, and automation vendors.

The ideal candidate brings hands-on PLC programming, FAT/SAT leadership, and multi-vendor integration experience, with travel as required and a focus on production readiness.