TITLE: Senior Controls Engineer
REPORTS TO: Plant Manager
DEPARTMENT: Maintenance / Engineering
LOCATION: Ashtabula, Ohio
Position Summary
The Senior Controls Engineer provides technical leadership and comprehensive electrical and controls engineering support to internal and external customers. This individual leads complex automation projects from concept through commissioning and run-off, establishes and maintains PLC and controls standards, and mentors and develops junior engineers and technicians.
The role requires strong technical expertise in industrial networking, including hardware, specifications, and limitations, along with proficiency in AutoCAD, electrical symbols and standards used in schematic control diagrams and instrumentation loop diagrams, and extensive experience with equipment commissioning.
Qualifications & Experience
- Bachelor's degree in Electrical Engineering, Controls Engineering, Automation Engineering, or a related technical field preferred; equivalent experience will be considered.
- 10+ years of controls or electrical engineering experience within a manufacturing environment, including 2–3 years of project leadership, technical leadership, or team oversight.
- Advanced technical expertise in motor controls, process controls, PLC and HMI programming, and industrial communication protocols.
- Hands-on experience with servo systems, inverters, variable frequency drives (VFDs), and CNC equipment.
- Strong working knowledge of applicable electrical and industrial safety standards, including NFPA 70, NFPA 70E, NFPA 79, and UL 508A.
Duties and Responsibilities
- Lead major automation and capital projects, managing timelines, budgets, and quality.
- Oversee projects from design and planning through installation, startup, and final testing.
- Mentor and provide technical guidance to Controls Engineers, technicians, and electricians.
- Review electrical designs, PLC programs, drawings, and technical work completed by others.
- Work with Operations, Maintenance, Quality, and R&D teams to plan and prioritize projects.
- Design and improve electrical systems, machine safety features, and equipment safeguards.
- Perform arc flash studies and maintain required electrical safety labels.
- Create electrical drawings, wiring diagrams, system layouts, and project specifications.
- Develop and support PLC, HMI, servo, VFD, and CNC programs.
- Lead troubleshooting and root cause reviews to resolve complex equipment issues.
- Oversee equipment testing, commissioning, installation, and startup activities.
- Review vendor designs and provide technical support during equipment installation.
- Develop and maintain PLC/HMI standards, procedures, backups, and system records.
- Identify and lead improvements in equipment safety, reliability, production speed, and efficiency.
- Use strong problem-solving, sound judgment, and clear communication to make technical decisions and work with employees at all levels.
AUTHORITY / DECISION MAKING
Works independently with minimal day-to-day supervision and is expected to make sound technical decisions on projects within their scope. Has authority to set and approve controls standards and design approaches, within company guidelines, procedures, and employee relations policy. Escalates budget, safety-critical, or cross-department issues to the R&D Manager.
WORK ENVIRONMENT
The work environment characteristics described here are representative of those an employee encounters while performing the essential functions of this job. The role splits time between office settings and manufacturing/plant floor areas, with exposure to noise, moving equipment, and industrial conditions. Reasonable accommodation may be made to enable individuals with disabilities to perform the essential functions.
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