Staff / Principal PLC Controls Engineer

Mach10 Solutions

Berkeley (CA)

On-site

USD 120,000 - 160,000

Full time

47 hours ago

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Job summary

Mach10 Solutions seeks a Staff/Principal PLC Controls Engineer to lead PLC software development, integration, and commissioning for high-volume test stands in a production environment.

You will migrate logic to product controllers, implement robust PLC-to-controller communication, and validate instrumentation and I/O across legacy and upgraded platforms. The role requires autonomy and strong cross-functional collaboration.

Qualifications

Extensive experience in a Staff/Principal level PLC/Controls engineering role.
Proven hands-on development and modification of complex PLC programs.
Advanced Structured Text programming.
Experience with CODESYS or IEC 61131-3 environments and independent work.
Experience modifying legacy PLC codebases.
Architecting communication interfaces between PLCs and external product controllers.
Strong understanding of PLC architecture including I/O, sensors, and control systems.
Electrical troubleshooting: wiring, pinouts, control panels, I/O.
Experience with system integration, commissioning, or automated test equipment projects.
Autonomy and decisive technical decision-making.
Cross-functional collaboration.

Responsibilities

Create and maintain PLC software with CODESYS/ST.
Analyze control architectures with minimal supervision.
Migrate PLC logic to product controllers where appropriate.
Establish PLC-to-product-controller communication pathways.
Integrate product controllers into legacy and upgraded test stands.
Adjust PLC operations while preserving system reliability.
Diagnose issues in PLC logic, I/O, instrumentation, wiring, and panels.
Validate instrumentation interfacing with PLC for accurate signal scaling.
Provide electrical support for system integration and commissioning.
Lead test-stand commissioning to ensure production readiness.
Collaborate across electrical, mechanical, and systems teams.
Serve as the controls authority during integration and production readiness.
Identify bottlenecks and implement long-term solutions.
Enhance controls architecture to improve reliability and throughput.
Document all PLC modifications and commissioning results.

Skills

Senior PLC/Controls

Structured Text

CODESYS IEC61131-3

PLC debugging

PLC-to-controller comms

Electrical troubleshooting

Autonomy

Cross-functional collaboration

Tools

Beckhoff

Allen-Bradley

Siemens

Solid Edge

Siemens NX

CATIA

Creo

SolidWorks

AutoCAD

Job description

Staff / Principal PLC Controls Engineer – Test & Integration

Role Overview

We are looking for a highly skilled Staff or Principal-level PLC Controls Engineer to manage PLC programming, system integration, and the commissioning of sophisticated test platforms within our high-volume production facility.

Context for the Position

Our organization is currently expanding to achieve a 225-unit build capacity, necessitating a comprehensive upgrade to our test-stand infrastructure and control systems. While our current PLC framework is operational, we are shifting specific control logic from the PLC to dedicated product controllers, which requires establishing robust communication interfaces between these systems. This is an optimization and integration initiative rather than a greenfield development project. We need a seasoned expert to navigate the existing CODESYS and Structured Text environment, refine the logic, and implement necessary communication protocols independently. Additionally, you will play a key role in validating updated test stands—covering everything from instrumentation and signal scaling to I/O and control-panel integrity—to ensure full production readiness.

Your Responsibilities

Create, refine, and maintain PLC software utilizing CODESYS and Structured Text to ensure optimal system performance.
Analyze and interpret established control architectures with minimal supervision to drive project progress.
Determine which segments of existing PLC logic should be decommissioned, adjusted, or migrated to product controllers.
Establish seamless communication pathways between the PLC and product controllers to improve overall system efficiency.
Incorporate product controllers into both legacy and newly upgraded test-stand configurations.
Adjust proven PLC operations while maintaining the integrity and reliability of existing system performance.
Diagnose and resolve issues related to PLC logic, I/O, instrumentation, sensors, wiring, and control-panel hardware.
Validate that all instrumentation is correctly interfaced with the PLC to ensure accurate signal scaling and output.
Provide expert electrical support to help the team achieve successful system integration and commissioning.
Lead the commissioning of test stands to guarantee full operational readiness before production units arrive.
Collaborate across electrical, mechanical, and systems departments to foster a cohesive environment for resolving integration challenges.
Act as the primary technical authority for controls during the integration, commissioning, and production-readiness phases.
Rapidly identify technical bottlenecks and independently execute effective, long-term solutions.
Contribute to the enhancement of controls architecture to bolster test-system reliability and manufacturing throughput.
Maintain comprehensive documentation of all PLC modifications, system upgrades, and commissioning outcomes.

Technical Environment

CODESYS
Structured Text (ST)
PLC programming and controls architecture
PLC-to-product-controller communication
Product controllers
Industrial I/O
Sensors and instrumentation
Control panels and electrical systems
Automated test stands
System integration and commissioning
High-volume manufacturing equipment

Required Qualifications

Extensive experience in a Staff, Principal, or equivalent senior-level PLC/Controls engineering capacity.
Proven hands-on expertise in the development and modification of complex PLC programs.
Advanced proficiency in Structured Text programming.
Professional background using CODESYS or similar IEC 61131-3 environments with the capability to operate independently.
Demonstrated success in navigating and modifying legacy PLC codebases without significant oversight.
Experience architecting communication interfaces between PLCs and external product controllers.
Deep understanding of PLC architecture, including I/O, instrumentation, sensors, and control systems.
Strong electrical troubleshooting capabilities, specifically regarding wiring, pinouts, control panels, and PLC I/O.
Experience managing system integration, commissioning, or automated test equipment projects.
Ability to resolve complex technical issues spanning both PLC software and physical electrical hardware.
Capacity to work autonomously and make critical technical decisions with limited supervision.
Excellent interpersonal skills to facilitate effective cross-functional collaboration.

Preferred Qualifications

Experience with industrial PLC platforms such as Rockwell/Allen-Bradley or Siemens.
Familiarity with various industrial communication protocols.
Background in integrating embedded or product controllers into PLC-based systems.
Experience optimizing existing PLC architectures rather than building systems from scratch.
Experience with automated test stands, laboratory equipment, or production-grade test systems.
Experience supporting high-volume manufacturing environments.
Ability to read and interpret complex electrical schematics.
Experience with instrumentation scaling, signal validation, and I/O commissioning.

What We Are Looking For

This position demands more than standard troubleshooting; we require a Subject Matter Expert who can analyze existing architectures, execute precise code modifications, and validate the physical system. The ideal candidate will take full ownership of the PLC program and determine the optimal path for logic migration, communication protocols, and hardware validation to ensure seamless operation without needing constant guidance.

Success Metrics

Success in this role is defined by your ability to hit the ground running and take full ownership of controls tasks. You will be instrumental in transitioning our PLC functionality, ensuring reliable communication, and validating test stands to support our 225-unit build rate. Your work will directly influence our production capacity and the overall reliability of our manufacturing operations. You should be proficient in PLC Troubleshooting, Electrical Schematics, Single/Three Phase Power, 120/208/240/480 Voltage Systems, Industrial Robot Programming, Design for Assembly (DFA), PLC Programming, SCADA, Electrical/Electronic Systems, High Voltage Systems, Equipment Installation & Wiring, Access Control Systems, and Aerospace Manufacturing. Technologies you will utilize include Variable Frequency Drives (VFD), various CAD software (Solid Edge, Siemens NX, Catia, Pro-E/Creo, Solidworks, Onshape, Autodesk Inventor, AutoCAD), diverse PLCs (Beckoff, Allen Bradley, Fanuc, Schneider Electric, Mitsubishi, Modicon, Omron, B&R, Siemens, Panasonic, Sigmatek), Vision Systems, Servo Motors, and Industrial Robots.

Our Story

From Montana to Nationwide Excellence

Founded in Montana, Mach10 Solutions has rapidly expanded to provide premium fabrication and engineering services across the United States. Our journey began with a simple mission: deliver precision engineering solutions at unprecedented speeds.

Today, we leverage cutting‑edge technology and exceptional talent to provide manufacturing services that consistently exceed expectations. With a focus on quality, speed and innovation, we’ve become the trusted partner for companies seeking competitive advantages through superior fabrication and design.

At Mach10, we don’t just build components – we forge lasting partnerships through reliability, expertise, and our commitment to pushing the boundaries of what’s possible.

Our Services

Precision Fabrication

State‑of‑the‑art manufacturing delivering tight‑tolerance components with uncompromising accuracy.

Design & Drafting

Comprehensive CAD modeling, documentation and DFM optimization to ensure flawless execution.

Field Services

Nationwide on‑site technical support, installation and maintenance from highly trained experts.

Quality Assurance

Rigorous inspection protocols guarantee every component meets or exceeds industry standards.

Project Management

End‑to‑end project coordination with clear communication and on‑time delivery.

Rapid Prototyping