Senior Controls System Engineer

• We are seeking Controls Systems Engineer to work on the design, programming, commissioning, and sustained operation of controls and automation systems across our manufacturing environment. This is a technical,

Description

• We are seeking Controls Systems Engineer to work on the design, programming, commissioning, and sustained operation of controls and automation systems across our manufacturing environment. This is a technical, individual-contributor role: you will architect and program PLC systems, build SCADA/HMI applications, integrate industrial robots and automation cells, and serve as the technical authority for controls integration across the MES, ERP, WMS, QMS, PLC, and SCADA layers. Working in a fast-paced manufacturing setting, you will operate with high autonomy and a strong bias for action—diving deep into PLC programming, SCADA system design, and controls architecture while ensuring daily production reliability, safety, and performance. Your scope spans pilot operations through high-volume production across diverse processes and lines. You thrive on the practical challenges of the factory floor—troubleshooting live equipment, improving cycle time and uptime, and turning a pilot line into a repeatable, high-yield production system. Key job responsibilities Controls Design & Development - Design and program PLC architecture (Siemens TIA Portal and/or Rockwell Studio 5000/ControlLogix), define programming standards, and develop controls design specifications for a scalable framework spanning pilot through high-volume production. - Enforce controls standards (hardware, software, networking); review and validate that system integrators and vendors deliver in strict compliance. - Design, deploy, and maintain the SCADA/HMI layer (e.g., Ignition, FactoryTalk, WinCC), providing real-time visibility into line performance, alarms, and production data. - Implement automation and robot integration (e.g., Fanuc, KUKA, ABB) across assembly and automation cells, ensuring standardized programming, safety compliance, and maintainability. - Develop functional safety designs (SafetyPLC, safety-rated networks) and apply equipment safety standards for all automated systems, ensuring compliance with industry regulations and Amazon safety requirements. MES & Systems Integration - Implement MES integration at the controls layer, bridging MES, ERP, WMS, QMS, PLC, and SCADA systems to ensure seamless data flow from the shop floor to enterprise systems. - Partner with the Factory Software team on system architecture, data models, and integration—defining clear interface boundaries and supporting coordinated deployment. - Build traceability, genealogy, and quality data capture at the controls layer to support analytics, yield improvement, and regulatory compliance. - Apply standards for connectivity protocols (OPC-UA, EtherNet/IP, PROFINET), data historians, and reporting infrastructure that enable data-driven decision making. Line Deployment, Commissioning & Ramp - Own the controls engineering scope for line deployment: design review, vendor coordination, FAT, SAT, commissioning, and ramp to high-volume production. - Coordinate system integrator relationships: define specifications, conduct design reviews, verify adherence to controls standards, and drive issue resolution. - Lead troubleshooting, optimization, cycle-time improvement, and reliability growth through production ramp to steady-state operations. - Collaborate with Operations, Process Engineering, and Quality teams to ensure controls solutions meet operational and production requirements. - Drive root cause analysis on system failures; implement countermeasures and preventive mechanisms to improve reliability and uptime (MTTR/MTBF). - Develop commissioning playbooks, validation protocols, and startup checklists that enable repeatable, rapid line launches. Technical Excellence & Sustained Operations - Support 24/7 production through on-call participation and escalation, diving deep on the factory floor to restore and improve automated systems. - Create and maintain knowledge management resources, troubleshooting databases, and continuous-improvement mechanisms for controls reliability. - Own technical documentation for electrical and control systems.

Basic Qualifications

• - Experience programming with at least one modern language such as Python, Ruby, Golang, Java, C++, C#, Rust - Experience with Linux/Unix - Experience with CI/CD pipelines build processes - Bachelor's degree in Computer Science, Engineering, Mathematics, or a related field - Experience with advanced automation controls systems - Experience in a fast-paced, automated, industrial, logistics, production or manufacturing environment - 4+ years of hands-on experience in controls engineering, industrial automation, or related disciplines. - Experience designing and programming PLC architecture (Siemens TIA Portal and/or Rockwell Studio 5000/ControlLogix). - Experience with SCADA/HMI system design, deployment, and management (e.g., Ignition, FactoryTalk, WinCC). - Experience coordinating with system integrators and verifying vendor compliance with controls standards. - Working knowledge of MES architecture and integration with ERP, WMS, QMS, and shop-floor systems.

Preferred Qualifications