Senior Controls Engineer - TPM

Robert Bosch Group; North Charleston (SC); On-site; USD 110,000 - 160,000; Full time

Benefits offered by this job

Time-off policy

PTO 16 days + 5 personal days

9 paid holidays

401(k) with generous match

Profit sharing bonus

Medical, dental, vision coverage

Onsite cafeteria

Onsite Starbucks

Student debt retirement savings match

Job summary

Robert Bosch Group seeks a Senior Controls Engineer with deep CoDeSys expertise for designing, programming, and commissioning complex control systems in manufacturing environments.

You will lead hardware/software integration, develop HMIs, and mentor junior engineers while ensuring safety and efficiency in production lines.

Qualifications

• Bachelor’s degree in Electrical/Mechatronics or related field; Master’s preferred.
• 7+ years in industrial control design, programming and commissioning.
• 3+ years programming CoDeSys for industrial machinery.
• Experience leading control system projects from concept to production.
• Strong knowledge of PLCs, HMIs, drives, sensors, actuators and networks.

Responsibilities

• Lead design and specification of complex control systems across hardware and network architecture.
• Develop electrical schematics, I/O lists, and wiring diagrams with electrical engineers.
• Define control strategies, safety interlocks, and production-oriented sequences.
• Program and debug CoDeSys in ST, FBD, LD, SFC; create reusable libraries.
• Integrate fieldbus protocols (EtherCAT, PROFINET, Modbus, CANopen) in CoDeSys.
• Develop/prep HMI/SCADA projects with strong operator usability and diagnostics.
• Lead on-site commissioning, testing and tuning to meet production targets.
• Mentor junior engineers; participate in design reviews and documentation.

Skills

CoDeSys programming

IEC 61131-3

Industrial networking

HMI/SCADA development

Electrical panel design

Safety systems

CAD drafting

Schematic reading

Manufacturing processes

OT/OT monitoring

Mentoring juniors

Education

Bachelor's in Electrical Engineering / Mechatronics / Computer Engineering

Master's degree (plus)

Tools

AutoCAD Electrical

EPLAN

Job description

Do you want beneficial technologies being shaped by your ideas? Whether in the areas of mobility solutions, consumer goods, industrial technology or energy and building technology - with us, you will have the chance to improve quality of life all across the globe. Welcome to Bosch.

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.
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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.
• 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
• 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.
• 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

Qualifications

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 60204), and their application in a manufacturing plant.

Experience with industrial safety systems (e.g., safety PLCs, light curtains, emergency stops) as applied to production equipment and personnel safety.

Familiarity with CAD software for electrical design (e.g., AutoCAD Electrical, EPLAN).

Ability to read and interpret complex electrical schematics and mechanical drawings.

Demonstrated understanding of manufacturing processes, including but not limited to: material handling, assembly, machining, packaging, process control, and quality inspection.

Knowledge of key manufacturing metrics such as OEE, cycle time, throughput, and their impact on control system design.

Soft Skills:Excellent analytical and problem‑solving abilities, particularly in diagnosing and resolving production issues.

Strong written and verbal communication skills, able to convey complex technical information to production, maintenance, and management teams.

Ability to work independently and as part of a multidisciplinary team, including collaboration with production operators and maintenance technicians.

Demonstrated leadership potential and ability to mentor.

Strong attention to detail and commitment to quality.

Ability to manage multiple priorities and meet deadlines in a fast‑paced manufacturing environment.

Additional Information

• Competitive Time Away from Work Policy
• Paid Time Off (PTO): 16 days (Up to 30 days based on seniority)
• Personal Days (PAA): 5days
• Company Paid Holidays: 9 days
• Industry Best Retirement Benefit
• 401k - 75% match up to the first 9% contribution
• Unique Bosch Defined Contribution (BDC) plan provides 100% company-funded 401(k) contributions, ranging from 2.5% to 6.5% of your pay, helping you secure your financial future
• Student Debt Retirement Savings Match
• Profit Sharing Bonus (CPrP) up to 10%
• Medical, dental, and vision coverage
• Onsite Cafeteria with multiplemenu options
• Onsite Starbucks Cafe

Your well-being matters at Bosch! We offer a competitive compensation and a benefits package designed to empower you in every area of your life. This includes premium health coverage, a 401(k) with generous matching, resources for financial planning and goal setting, ample paid time off, parental leave, and comprehensive life and disability protection. We're investing in your success! Bosch Benefits | Bosch in the USA

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