What does a Senior Controls Engineer do?
Controls engineers play pivotal roles in plant procedures and operations. They are central to many industries and are often required to have proficiency in electronics, mechanics, and engineering. They use their analytical skills to examine and improve a process or increase productivity, and they are responsible for checking that plant equipment is maintained correctly. They collaborate with other departments and outside parties to create and implement processes that increase efficiency.
Controls engineers troubleshoot issues with hardware and with processes, and they plan preventative maintenance. They strive to find creative solutions when problems and issues arise. They also assist in implementing predictive maintenance plans and analyzing plant processes to improve their expertise in electronics, engineering, and mechanics. Controls engineers need a minimum bachelor's degree in engineering, electrical, manufacturing, or mechanical engineering and two-to-four years of experience in related fields.
- Lead design control activities, author and review design controls.
- Develop all aspects of control systems, equipment, and machinery.
- Analyze, design and implement Robotic Process Automation (RPA) solutions.
- Assist with the development of technical reports or related documents.
- Own, maintain and approve all schematics for new and existing equipment.
- Act as the technical consultant for capital projects within the build.
- Develop control system graphics and configure control system databases.
- Provide input to the project lessons learned process.
- Prototype, test, and optimize GNC systems in both simulation and actual flight tests.
- Partner with cross-functional teams to define sensor, computing, network, and redundancy requirements.
- Assist in the development of machine specifications.
- Provide documentation and support to the field team.
- Promote a safe working environment by following all safety procedures.
- Appropriately escalate downtime situations to vendors or headquarters for support to restore equipment operation.
- Ensure compliance with applicable internal processes and regulations.
- You may also be responsible for completing the CAD drawings.
- Perform controls systems assessments to maintain and improve equipment reliability.
- Recommend hardware and software changes as well as upgrades to existing systems.
- Take initiative to identify opportunities for continuous improvement.
- Provide sketches, markups and direction to electrical designers to develop project drawings.
- Bachelor's or Graduate's Degree in mechanalectrical engineering, computer science, or engineering or equivalent experience.
- Experience with PLC, HMI, AutoCAD, C and RSLOGIX software and systems.
- Experience with controls design.
- Dedicated to problem solving and continuous improvement.
- Fluent in controls systems writing protocols, and databases.
- Comfortable with algorithm design and programmable logic practices.
Senior Controls Engineer Salaries
Average Base Pay
Senior Controls Engineer Career Path
Learn how to become a Senior Controls Engineer, what skills and education you need to succeed, and what level of pay to expect at each step on your career path.
Years of Experience Distribution
Senior Controls Engineer Insights
“18 hour days and expect you to drive to work and be efficient and effective.”
“MM is the best and has the best culture i have seen in my career.”
“Most people spend few years and then leave because working here leads to great career opportunities afterwards.”
“Their pay is very competitive and I was actually quite happy with my paycheck here.”
“WELD uses cutting edge technologies and currently is one of the best welding machines manufacturer in region.”
“Management cares about how you're doing outside of your work and is able to work with you to ensure you're able to succeed”
“Good benefits such as 100% 401k match up to 6% of your salary.”
“Good place to work and pay is good”
Senior Controls Engineer Interviews
Frequently asked questions about the role and responsibilities of a Senior Controls Engineer
When working as a Senior Controls Engineer, the most common skills you will need to perform your job and for career success are PLC Programming, HMI Programming, Consulting, PLC SCADA and Onboarding.
- Electronics Engineer
- Electronics Design Engineer
- Electrical Designer
- Electrical Engineer
The most common qualifications to become a Senior Controls Engineer is a minimum of a Bachelor's Degree and an average of 0 - 1 of experience not including years spent in education and/or training.