Senior Controls Engineer - TPM

Boschgroup; Charleston (SC); On-site; USD 110,000 - 140,000; Full time

Job summary

Boschgroup is seeking a Senior Controls Engineer with extensive experience in industrial automation and CoDeSys programming. The role focuses on design, development, implementation, and commissioning of advanced control systems for manufacturing processes.

You will lead technical initiatives, mentor junior engineers, and ensure adherence to safety and industry standards while optimizing OEE and production efficiency.

Qualifications

• Minimum 7+ years in industrial control systems design and commissioning.
• Hands-on experience programming and developing complex CoDeSys applications for production lines.
• Proven ability to lead technical control system projects from concept to production readiness.

Responsibilities

• Lead the design and specification of complex control systems including hardware selection and network architecture.
• Program, test, and debug PLC logic using CoDeSys in IEC 61131-3 languages.
• Lead on-site commissioning, testing, and tuning to meet production targets and minimize downtime.
• Create and maintain comprehensive technical documentation and ensure compliance with industry standards.
• Provide guidance and mentorship to junior controls engineers and participate in design reviews.
• Identify opportunities for process improvement and standardization in manufacturing environments.

Skills

CoDeSys programming

Industrial networking

HMI/SCADA development

Electrical panel design & safety

Education

Bachelor's degree in Electrical Engineering, Mechatronics Engineering, or Computer Engineering

Master's degree (plus)

Tools

CoDeSys

HMI/SCADA platforms

Job description

We are seeking a highly skilled and experienced Senior Controls Engineer with a strong background in industrial automation and a deep expertise in CoDeSys for PLC programming. The successful candidate will play a critical role in the design, development, implementation, and commissioning of complex control systems for our [products/systems/manufacturing processes]. This role requires a hands‑on approach, strong problem‑solving skills, and the ability to lead technical initiatives while mentoring junior engineers, all with a keen understanding of manufacturing principles and operational efficiency.

Key Responsibilities

System Design & Architecture

• Lead the conceptualization, design, and specification of complex control systems, including hardware selection (PLCs, HMIs, drives, sensors, actuators) and network architecture.
• Develop detailed electrical schematics, I/O lists, and wiring diagrams in collaboration with electrical engineers.
• Define control strategies, safety interlocks, and operational sequences, always considering manufacturing process flow, cycle time optimization, and overall equipment effectiveness (OEE).

CoDeSys Programming & Development (Core Responsibility)

• Expertly program, test, and debug PLC logic using CoDeSys (IEC 61131-3) in various languages (ST, FBD, LD, SFC).
• Develop and implement reusable CoDeSys libraries, function blocks, and structured text routines, ensuring solutions are robust, maintainable, and scalable for production environments.
• Integrate and configure various fieldbus protocols (e.g., EtherCAT, PROFINET, Modbus TCP/IP, CANopen) within the CoDeSys environment.
• Develop and integrate HMI/SCADA applications using CoDeSys visualization or other compatible platforms, prioritizing operator usability, process visibility, and diagnostic capabilities for manufacturing personnel.

Commissioning & Troubleshooting

• Lead the on-site commissioning, testing, and tuning of control systems, ensuring optimal performance and adherence to specifications, with a focus on achieving production targets and minimizing downtime.
• Perform advanced troubleshooting and diagnostics of complex hardware and software issues, often under pressure in a live manufacturing environment.
• Collaborate with mechanical, electrical, and software engineers to resolve system integration challenges, understanding their impact on the manufacturing line.

Documentation & Standards

Create and maintain comprehensive technical documentation, including functional specifications, design documents, test plans, and as-built drawings, which are essential for long-term manufacturing support and maintenance. Ensure all control system designs and implementations comply with relevant industry standards (e.g., UL, CE, NFPA, ISO, ANSI) and manufacturing specific regulations. Adhere to established coding standards and best practices for CoDeSys development.

Project Leadership & Mentorship

Lead technical aspects of projects, including scope definition, scheduling, and resource allocation, considering production timelines and resource availability within a manufacturing context. Provide technical guidance and mentorship to junior controls engineers, fostering their development in CoDeSys and control system design with an emphasis on practical manufacturing applications. Participate in design reviews and provide constructive feedback.

Continuous Improvement & Manufacturing Optimization

Stay abreast of new technologies, industry trends, and best practices in industrial automation and CoDeSys, specifically those applicable to improving manufacturing processes and efficiency. Proactively identify opportunities for process improvement, standardization, cost reduction

Education

Bachelor's degree in Electrical Engineering, Mechatronics Engineering, Computer Engineering, or a closely related engineering discipline from an accredited university. Master's degree a plus.

Experience

Minimum of 7+ years of progressive experience in industrial control systems design, programming, and commissioning, with a significant portion in manufacturing or production environments. Minimum of 3+ years of dedicated, hands‑on experience programming and developing complex applications with CoDeSys (all versions/compatible platforms are valuable) for industrial machinery or production lines. Proven experience leading technical aspects of control system projects, from concept to production readiness.

Technical Skills (Must-Haves)

• Expert-level proficiency in CoDeSys (IEC 61131-3) programming.
• Strong understanding of industrial networking protocols (e.g., EtherCAT, PROFINET, Modbus TCP/IP, CANopen, Ethernet/IP).
• Proficient with HMI/SCADA development and integration, with an emphasis on intuitive operator interfaces and robust data acquisition for manufacturing analytics.
• Solid understanding of electrical control panel design principles and safety standards (e.g., NFPA 79, UL 508A, EN ISO 13489, IEC 6020)