Senior Staff Controls Engineer

Job Description

• Serve as the technical lead for controls engineering and automation standards
• Own site-wide controls architecture, software standards, and OEM equipment specifications
• Ensure OEM-delivered equipment aligns with established internal automation standards
• Review and approve PLC code, HMIs, safety systems, and controls designs from vendors
• Lead FAT/SAT activities and travel to OEM sites during equipment acceptance testing
• Support commissioning and startup of new production equipment
• Drive integration of robotics, vision systems, AGVs, conveyors, and material handling equipment
• Define and maintain safety PLC standards and functional safety requirements
• Partner with vendors, OEMs, integrators, and internal engineering teams to ensure successful deployments
• Troubleshoot complex controls, networking, and automation issues Job Description: Insight Global is seeking a Senior Controls Engineer for a leading advanced manufacturing client in North Carolina. This is a staff-level technical leadership role focused on automation standards, controls architecture, and OEM equipment integration for a large-scale facility expansion. The ideal candidate has deep Siemens and Allen-Bradley controls expertise, experience authoring controls standards, and the ability to lead vendors and engineering teams through equipment design reviews, FATs, commissioning, and startup activities. This role is ideal for someone who enjoys owning automation strategy, driving consistency across production systems, and serving as the controls subject matter expert for a highly automated manufacturing environment.

Skills and Requirements

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

• 8+ years of industrial controls/automation experience

• Expert-level Siemens and Allen-Bradley/Rockwell PLC programming and commissioning

• Experience authoring and enforcing controls standards used by engineers, OEMs, and vendors

• Strong knowledge of ISA-88 Batch Control principles

• Experience reviewing and approving OEM controls architecture, PLC code, and HMI standards

• Functional Safety expertise:

• IEC 62061

• IEC 61508

• ISO 13849

• SIL-rated safety systems

• Experience with machine vision systems (Cognex, Keyence preferred)

• Knowledge of Ethernet/IP, Profinet, EtherCAT, OPC UA, and Modbus

• Experience with robotics, conveyors, servos, VFDs, and automated material handling systems Technical leadership/team lead experience

• SCADA development experience (Ignition, FactoryTalk, Wonderware)

• Experience with MES/SCADA integrations

• Robotics experience (Fanuc, ABB, KUKA)

• AGV integration experience

• Python or C++ experience

• Background working for OEMs or System Integrators Experience in automotive, aerospace, defense, chemical, metals, or greenfield manufacturing environments

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].