Senior Controls Engineer

Senior Controls Engineer

Location: McElhattan, PA
Direct Hire

We are seeking an experienced Controls Engineer to join our manufacturing facility in McElhattan, PA. This role is responsible for specifying, designing, implementing, and upgrading advanced control systems and automation solutions across production equipment and associated machinery.

The Controls Engineer will serve as a technical leader and mentor, working closely with Engineering, Maintenance, and Production teams to drive equipment performance, reliability, and continuous improvement. This position has a direct impact on plant performance through machine optimization and engineering-based upkeep.

Key Responsibilities

Collaborate with Engineering, Maintenance, Production, OEMs, vendors, and contractors to design, install, commission, and start up new equipment and process control systems

Review and approve electrical and controls component selection, electrical designs, and control system software modifications

Lead machine acceptance testing, identify performance gaps, and resolve startup and commissioning issues

Specify, design, and support DCS, PLC, HMI, servo systems, motors, drives, sensors, vision systems, and data collection platforms in alignment with First Quality controls standards

Evaluate automation and electrical equipment from multiple suppliers and recommend optimal solutions

Design and implement complex program modifications in PLC logic, DCS systems, HMI applications, and servo controllers to improve equipment and system performance

Perform advanced troubleshooting of electrical, mechanical, and process issues, leading and mentoring others through root-cause resolution

Partner with the internal MES team to develop, improve, and maintain machine data collection systems

Lead and support small capital improvement projects

Stay current on emerging controls technologies, industry trends, and applicable health and safety standards

Proactively identify opportunities to improve operational efficiency, reliability, and throughput

Initiate, lead, and manage continuous improvement initiatives from concept through completion

Provide technical and operational training to Controls, Production, Maintenance, Warehouse, and other teams

Foster a sense of urgency and accountability while maintaining a strong safety-first mindset

Support off-shift and after-hours troubleshooting as required

Qualifications

• Bachelors degree in one of the following or a related field:

  • Electrical Engineering

  • Electro-Mechanical Engineering

  • Mechatronics

  • Automation Engineering

  • Robotics Engineering

  • Manufacturing Engineering

Minimum of 8 years of experience working with industrial control systems in a manufacturing environment

Advanced knowledge of electrical theory and industrial automation principles

Strong hands-on experience with PLC hardware and software (Rockwell and Siemens), servo control systems, and HMIs

Ability to create and modify electrical schematics using AutoCAD

Working knowledge of mechanical, pneumatic, and hydraulic systems

Formal training in functional machine safety and safe machine design, including Safety Risk Assessments

Knowledge of or formal training in Industrial Automation Security (ISO 62443)

Lean Six Sigma Green Belt or Black Belt experience (preferred, not required)

Root Cause Analysis experience (preferred, not required)

Strong verbal and written communication skills, including technical documentation

Excellent analytical, troubleshooting, and problem-solving abilities

Proficiency with Microsoft Office, particularly Outlook and Excel

Ability to work effectively in a fast-paced manufacturing environment

Work Environment & Physical Requirements

Regular exposure to electrical and mechanical equipment

Occasional exposure to high-noise environments

Potential exposure to dust during certain tasks

Ability to work overtime, weekends, and be on-call as needed