Senior Controls Engineer

Job Description

Day-to-Day:

• Lead automation acceptance, FAT, SAT, and commissioning activities for a large manufacturing expansion
• Develop standardized FAT/SAT protocols and manage program-wide punch lists
• Review OEM controls architectures, schematics, PLC code, and HMI designs
• Program, modify, troubleshoot, and commission Siemens and Rockwell PLCs
• Coordinate integration of robotics, conveyors, AGVs, vision systems, servos, and material handling equipment
• Validate controls, safety interlocks, alarms, networking, and system functionality
• Partner with OEMs, Tier 2 vendors, and system integrators to ensure successful deployment
• Support MES/SCADA connectivity and automation system performance
• Serve as the senior escalation point for complex controls and commissioning issues Job Description: Insight Global is seeking a Sr. Controls Engineer (FAT/SAT & Commissioning) for a rapidly growing advanced manufacturing client in North Carolina. This engineer will own the automation acceptance process across a major manufacturing facility expansion, serving as the bridge between OEMs, system integrators, and automation vendors. The ideal candidate is a commissioning-focused controls engineer who can both write and troubleshoot PLC code while driving FAT/SAT execution, equipment acceptance, and multi-vendor integration efforts. This role is highly visible, highly technical, and ideal for someone who enjoys travel, commissioning, complex automation systems, and ensuring equipment is production-ready before launch.

Skills and Requirements

• BS/MS in Electrical Engineering, Automation Engineering, Mechatronics, or related field

• 7+ years of industrial automation and controls engineering experience

• Strong hands-on PLC programming and commissioning experience with Siemens and Allen-Bradley/Rockwell

• Experience leading FAT, SAT, commissioning, and large-scale equipment acceptance campaigns

• Experience creating FAT/SAT protocols, punch lists, and acceptance documentation

• Multi-vendor integration experience with OEMs, system integrators, and automation suppliers

• Strong knowledge of Ethernet/IP, Profinet, OPC UA, Modbus, and industrial networking

• Experience with servos, VFDs, conveyors, robotic cells, motion control, and automated material handling systems Ability to troubleshoot controls, networking, safety, and automation issues during commissioning

• EtherCAT experience

• System Integrator or Machine OEM background

• Robotics experience (Fanuc, ABB, KUKA)

• Machine vision experience (Cognex, Keyence)

• SCADA/MES experience (Ignition, FactoryTalk, Wonderware)

• AGV integration experience

• Python or C++ exposure

• Experience in Defense, Aerospace, Automotive, Chemical, Metallurgical, or Greenfield manufacturing environments CSV/GAMP 5 validation experience

We are a company committed to creating diverse and inclusive environments where people can bring their full, authentic selves to work every day. We are an equal employment opportunity/affirmative action employer that believes everyone matters. Qualified candidates will receive consideration for employment without regard to race, color, ethnicity, religion, sex (including pregnancy), sexual orientation, gender identity and expression, marital status, national origin, ancestry, genetic factors, age, disability, protected veteran status, military or uniformed service member status, or any other status or characteristic protected by applicable laws, regulations, and ordinances. If you need assistance and/or a reasonable accommodation due to a disability during the application or the recruiting process, please send a request to [email protected].