Senior Controls Specialist

Job Summary

We are seeking an experienced Senior Controls Specialist to join our team and play a key role in the design, development, implementation, optimization, and commissioning of control systems for automated machinery and industrial equipment.

The successful candidate will have strong hands-on experience with PLC programming, HMI development, SCADA integration, robotics, motion control, industrial networking, and machine safety systems. This role will work closely with mechanical designers, electricians, assemblers, and project teams to ensure controls systems are properly integrated throughout the machine build process.

The Senior Controls Specialist will also provide technical guidance to junior team members and support troubleshooting, commissioning, and customer requirements throughout the project lifecycle.

Key Responsibilities

• Lead the design and development of industrial control systems based on customer specifications and project requirements.
• Design, program, configure, test, and troubleshoot PLC-based control systems, primarily using Allen-Bradley.
• Develop and modify HMI applications, including operator interfaces, alarms, diagnostics, and machine controls.
• Integrate and troubleshoot SCADA systems and industrial communication networks.
• Program, configure, integrate, and troubleshoot ABB and Fanuc robotic systems.
• Develop and troubleshoot motion control and servo applications.
• Configure and troubleshoot industrial networks, IO-Link, and other automation communication systems.
• Develop and implement machine safety systems, including safety PLCs, safety devices, interlocks, and emergency-stop systems.
• Collaborate with mechanical designers, electricians, assemblers, and project managers to ensure seamless integration of controls throughout machine builds.
• Support the integration of electrical, pneumatic, mechanical, robotic, and automation systems.
• Develop and troubleshoot pneumatic control systems and assist with pneumatic design.
• Support machine vision applications and integration where required.
• Prepare and maintain electrical schematics, I/O lists, control documentation, and other project documentation.
• Use AutoCAD Electrical or EPLAN to develop and modify electrical/control drawings.
• Participate in machine testing, debugging, FAT, installation, start-up, and commissioning activities.
• Provide on-site technical support and troubleshooting at customer facilities as required.
• Provide technical guidance and mentorship to junior controls team members.
• Work closely with project teams to ensure controls projects are completed on schedule and according to customer requirements.
• Provide technical support for troubleshooting and resolving complex controls and automation issues.
• Maintain compliance with applicable industry standards, customer specifications, and safety requirements.

Qualifications

• 8–10+ years of experience in industrial controls, automation, or a related field.
• Minimum 5 years of hands-on experience in industrial automation, with 10+ years preferred, particularly within the automotive or manufacturing industry.
• Advanced knowledge and hands-on experience with Allen-Bradley PLCs is required.
• Experience with Omron and Siemens PLC platforms is considered an asset.
• Advanced experience with ABB and Fanuc robotics is required.
• Strong knowledge of machine safety systems and safety setup.
• Experience with industrial networking and IO-Link.
• Hands-on experience with motion control and servo applications.
• Experience with HMI development and SCADA integration.
• Experience with AutoCAD Electrical or EPLAN.
• Experience with pneumatic system design.
• Vision system/application experience is considered an asset.
• Strong electrical, controls, automation, and troubleshooting skills.
• Excellent communication, analytical, and problem-solving skills.
• Ability to work independently and collaborate effectively with multidisciplinary teams.
• Strong project management and organizational skills.
• Willingness to travel to customer sites for installation, commissioning, and technical support.
• Degree or Diploma in Electrical Engineering, Controls Engineering, Automation, Mechatronics, or a related field is required.