Sr Controls Engineer - Automation/PLC

SAI SYSTEMS; Michigan; On-site; USD 90,000 - 130,000; Full time

Job summary

SAI SYSTEMS in Michigan is seeking a Senior Controls Engineer to lead controls engineering on automation projects, owning design through commissioning. You will work hands-on in a shop environment to program, configure, and troubleshoot automated machinery, travel to customer facilities, and act as the primary technical contact for controls issues.

Responsibilities include designing PLC/HMI solutions using Allen‑Bradley Studio 5000 and Siemens TIA Portal, developing Fanuc robot integration, and

Qualifications

• Bachelor's degree in Electrical Engineering, Controls Engineering, Systems Engineering, or equivalent experience.

Responsibilities

• Lead controls engineering activities on assigned projects.

Skills

Controls engineering

Industrial automation

PLC programming

HMI development

Fanuc robotics

Technical leadership

Electrical schematics reading

Cross-functional communication

Education

Bachelor's degree in Electrical/Controls/Systems Engineering

Tools

Allen-Bradley Studio 5000

RSLogix/Studio 5000

Siemens TIA Portal

Step 7

FactoryTalk View

WinCC

ROBOGUIDE

Fanuc robot programming

Job description

Job Description

Job Description

Position Summary

We are seeking a highly skilled Senior Controls Engineer with deep expertise in industrial automation to join our team. In this role, you will serve as the technical lead for controls engineering activities on automation projects, owning all controls-related issues from design through commissioning.

The ideal candidate will work hands-on in a shop environment to program, configure, and troubleshoot automated machinery, support customer buyoffs, and travel to customer facilities for installation and startup activities. You will act as the primary technical point of contact for controls issues on assigned projects, driving resolution while keeping management informed of project status, risks, and technical challenges.

Key Responsibilities

• Serve as the technical lead for all controls engineering activities on assigned projects
• Identify, elevate, and resolve controls-related technical issues in a timely manner
• Communicate project status, technical risks, and open issues clearly to management and project stakeholders
• Design, develop, and program PLC-based control systems using:
• • Allen-Bradley (Studio 5000 / RSLogix)
  • Siemens (TIA Portal / Step 7)
• Develop and maintain HMI applications for operator interfaces and system visualization
• Program, configure, and commission Fanuc industrial robots including:
• • Robot setup
  • Path programming
  • Integration with surrounding automation systems
• Work in-shop during machine build and pre-shipment phases to:
• • Program systems
  • Configure hardware
  • Troubleshoot controls issues
• Support customer buyoffs and resolve punch-list items prior to shipment
• Travel to customer facilities for:
• • Installation
  • Startup
  • Commissioning
  • Technical support
• Perform system integration testing and troubleshoot hardware/software issues during commissioning and post-installation
• Collaborate with project engineers, mechanical teams, electricians, and customers to define and implement controls requirements
• Develop and maintain controls documentation including:
• • Functional specifications
  • I/O lists
  • Electrical schematics
  • Operator manuals
• Provide remote and on-site technical support after system commissioning
• Mentor junior engineers and contribute to internal programming standards and best practices

Qualifications

• Bachelor's degree in Electrical Engineering, Controls Engineering, Systems Engineering, or equivalent experience
• 3+ years of hands-on experience in industrial controls engineering
• Required proficiency with both:
  Candidates without demonstrated experience in both platforms will not be considered.
• • Allen-Bradley PLC platforms (Studio 5000 / RSLogix)
  • Siemens PLC platforms (TIA Portal / Step 7)
• Experience programming and commissioning Fanuc robots
• ROBOGUIDE experience preferred
• Strong HMI development experience using:
• • FactoryTalk View
  • WinCC
  • Or equivalent platforms
• Experience with:
• • Vision systems
  • Servo and motion control systems
  • Safety system design including Safety PLCs, light curtains, and area scanners
• Familiarity with industrial networking protocols including:
• • EtherNet/IP
  • Profinet
  • DeviceNet
• Ability to read and interpret:
• • Electrical schematics
  • Panel layouts
  • Wiring diagrams
• Proven ability to lead technical efforts and communicate effectively with management, customers, and project teams
• Willingness and ability to travel to customer plant sites as required

Preferred Qualifications

• Familiarity with SCADA systems and MES integration
• Prior experience in:
• • Automotive manufacturing
  • Food & Beverage
  • Heavy industrial manufacturing
• Experience with machine automation, robotic cells, and custom equipment integration

Work Environment

• Hands-on shop environment with machine builds and testing activities
• Travel required for installation, commissioning, and customer support
• Combination of office, manufacturing floor, and customer site work

Compensation & Benefits