Senior Controls System Engineer
Posted Updated
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.
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.