Role: Sr. Controls Engineer

Location: Fairport, NY

Your Impact

As a Senior Controls Engineer, you will play a critical role in advancing Qualitrol's manufacturing automation strategy by leading the design, implementation, and continuous improvement of industrial control systems across our manufacturing operations. You will drive automation excellence by developing reliable, scalable, and intelligent manufacturing solutions that improve safety, quality, productivity, and equipment performance.

Working closely with Manufacturing, Quality, Operations, IT, Product Engineering, and the Smart Factory Data Engineer, you will lead initiatives that strengthen Qualitrol's Industry 4.0 and Smart Manufacturing capabilities through connected equipment, advanced controls, data-driven decision making, and AI-enabled engineering solutions. You will also provide technical leadership, mentor junior engineers, and lead capital automation projects that support Qualitrol'slong-term operational excellence and growth objectives.

Here’s Where You’ll Demonstrate Your Proficiency

• Configure PLCs, HMIs, SCADA systems, sensors, and industrial devices to provide reliable operational data to manufacturing information systems.
• Collaborate with the Smart Factory Data Engineer to enable secure connectivity between shop-floor equipment, Industrial IoT platforms, MES systems, and cloud-based analytics solutions.
• Support implementation of industrial communication protocols including OPC-UA, MQTT, Ethernet/IP, and Modbus to improve equipment connectivity and data availability.
• Assist in validating manufacturing data quality, equipment signals, and production event data used for dashboards, reporting, and operational analytics.
• Participate in Smart Factory and Industry 4.0 initiatives by supporting connected manufacturing technologies, edge devices, and digital production systems.
• Work with Operations, Quality, and IT to improve equipment performance, data visibility, and manufacturing efficiency through automation.
• Analyze equipment and process performance data while partnering with the Smart Factory Data Engineer to improve manufacturing visibility, operational analytics, equipment utilization, OEE, and continuous improvement initiatives.

The Successful Candidate Will Demonstrate the Following Skills and Experience

• Bachelor's degree in Electrical Engineering, Electromechanical Engineering, Controls Engineering, or a related technical field.
•  8+ years of experience in controls engineering, industrial automation, manufacturing control systems, and automation project leadership.
• Strong experience designing, programming, commissioning, and troubleshooting PLC platforms such as Allen-Bradley/Rockwell, Siemens, Schneider Electric, or Mitsubishi.
• Experience developing and supporting HMI and SCADA systems including FactoryTalk View, Ignition, WinCC, Wonderware, or equivalent platforms.
• Strong knowledge of industrial communication protocols including Ethernet/IP, Profinet, Modbus TCP, DeviceNet, OPC UA, and related industrial networking technologies.
• Experience with variable frequency drives (VFDs), servo systems, motion control, robotics, machine vision, and automated manufacturing equipment.
• Ability to read, interpret, and develop electrical schematics, control panel drawings, wiring diagrams, and P&IDs.
• Demonstrated expertise in troubleshooting complex automation systems using structured root cause analysis and implementing sustainable corrective actions.
• Experience leading automation and capital improvement projects while collaborating with Manufacturing, Quality, Operations, Maintenance, and Engineering teams.
• Working knowledge of Lean Manufacturing, Six Sigma, continuous improvement methodologies, and manufacturing performance metrics such as OEE.
• Lead complex PLC, HMI, SCADA, robotics, motion control, and machine vision projects from concept through commissioning.
• Own automation standards, controls architecture, and cybersecurity best practices.
• Lead CAPEX projects including vendor management, FAT/SAT, startup, and validation.
• Mentor junior engineers and provide technical leadership across manufacturing.
• Drive reliability improvements, root cause analysis, OEE improvements, and AI-enabled automation initiatives.

Smart Manufacturing & Digital Skills

• Experience utilizing Artificial Intelligence (AI) tools to improve engineering productivity, troubleshooting, documentation, programming assistance, and process optimization.
• Demonstrated willingness to continuously learn and adopt emerging AI technologies to enhance manufacturing, automation, and engineering processes.
• Basic understanding of Industrial Internet of Things (IIoT) concepts connected manufacturing architectures, and Smart Factory initiatives.
• Familiarity with manufacturing data collection systems, industrial historians, and production data analytics.
• Exposure to industrial data connectivity technologies including OPC UA, MQTT, and industrial edge gateways.
• Experience supporting manufacturing dashboards, KPI reporting, or production analytics is preferred.
• Familiarity with Manufacturing Execution Systems (MES), ERP systems, SQL databases, or manufacturing data platforms is preferred.
• Ability to collaborate effectively with Software Engineering, IT, Data Engineering, and Digital Manufacturing teams to support factory automation and digital transformation initiatives.

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