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JOB SUMMARY:

The Senior Controls Engineer is a key technical leader responsible for the design, development, implementation, and sustainment of automated control systems across manufacturing operations. This role combines deep hands-on expertise in PLC, HMI, SCADA, robotics, and industrial networks with the ability to drive system architecture decisions, establish standards, and mentor controls engineering talent.

The Senior Controls Engineer leads the full lifecycle of controls engineering projects—from concept and design through commissioning and continuous improvement—and serves as a primary technical authority for internal stakeholders and external partners. The role plays a central part in advancing Industry 4.0 and smart manufacturing initiatives by integrating data-driven, connected automation solutions into the production environment.

ROLE SCOPE & CAREER LEVEL EXPECTATIONS:

This role is expected to operate with a high degree of autonomy and technical authority. The Senior Controls Engineer is accountable for leading complex initiatives, influencing technical direction beyond a single cell or line, and driving consistency across equipment, systems, and sites.

Key expectations at this level include:

• Independently leading complex, multi-discipline controls projects from concept through sustainment.

• Making and defending technical decisions related to system architecture, platforms, and standards.

• Providing guidance and technical direction to other engineers and technicians without direct supervision.

• Influencing plant-level and regional controls strategies through standards development and best practices.

• Representing the controls function in cross-functional and leadership discussions.

• Demonstrate leadership‑level availability and schedule flexibility to support plant operations during critical events, including off‑shift commissioning, escalations, and systemic issue resolution.

• Set expectations and coordinate coverage plans to ensure effective controls and automation support across operating hours.

• Responsibilities and expectations for this role are cumulative by level.

Advancement does not remove prior responsibilities; instead, each level retains accountability for all expectations of previous levels while expanding scope, technical judgment, leadership influence, and ownership.

Higher level roles are expected to demonstrate greater depth of knowledge, broader system ownership, and increased responsibility for quality, safety, reliability, documentation, and outcomes across automation and industrial systems.

ESSENTIAL JOB DUTIES AND RESPONSIBILITIES:

Technical Leadership & Execution:

• Lead and support controls engineering efforts for new equipment launches and existing production systems.

• Design, program, commission, and troubleshoot PLC, HMI, SCADA, vision, and robotic systems.

• Serve as the technical lead for complex troubleshooting and root-cause analysis impacting safety, quality, throughput, and uptime.

• Define scopes of work, technical requirements, and acceptance criteria for controls-related projects.

• Support installation, startup, and sustained production activities on the plant floor and at customer sites as required.

Controls Architecture & Standards:

• Lead system architecture reviews and establishes controls standards, best practices, and documentation requirements.

• Define and maintain electrical, controls, and equipment standards for both new and existing manufacturing assets.

• Oversee controls documentation, backups, version control, and lifecycle management of production equipment.

• Evaluate existing hardware and software platforms and recommend improvements to reliability, maintainability, and scalability.

Industry 4.0 / IIoT Enablement:

• Lead Industrial IoT (IIoT) initiatives across the Mirrors Division within the assigned region.

• Design, deploy, and support IIoT solutions including data acquisition, edge computing, industrial networking, and enterprise system integration.

• Drive adoption of OPC UA, MQTT, MES connectivity, data historians, and other smart manufacturing technologies aligned with corporate architecture standards.

• Develop and maintain site-level standard operating procedures supporting a structured pilot → scale → sustain approach.

• Coordinate implementations and system changes with local operations while ensuring compliance with data residency, cybersecurity, and lawful data-handling requirements.

• Develop and implement digital twins for critical assets and flows; enable event-driven alerts, e-Andon, and prescriptive actions via control towers and MES/WMS workflows.

Performance, Reliability & Continuous Improvement:

• Lead initiatives to reduce unplanned downtime and improve overall equipment effectiveness (OEE).

• Support continuous improvement efforts focused on reliability, cost reduction, and energy efficiency.

• Ensure compliance with automotive customer requirements and internal manufacturing standards.

• Perform other duties as assigned to support department goals and growth in technical skills.

Cybersecurity & Safety:

• Support OT cybersecurity improvements aligned with IEC 62443 and corporate security frameworks.

• Ensure appropriate implementation of industrial network segmentation, firewalls, access controls, and secure remote access.

• Assume responsibility for machine safety systems and controls-related safety compliance on assigned equipment.

Mentorship & Collaboration:

• Provide technical mentorship, coaching, and daily work guidance to junior and mid-level controls engineers.

• Lead technical reviews and promote knowledge sharing to improve team capability and consistency.

• Collaborate with Operations, Maintenance, IT/Digital, Engineering, Quality, Supply Chain, and corporate Industry 4.0 teams.

• Act as a technical interface with external vendors, system integrators, and customers.

QUALIFICATIONS:

The following qualifications are required to successfully perform the Senior Controls Engineer role. These requirements reflect the expected technical depth, decision-making authority, and leadership scope associated with a senior-level engineering role.

• Experience with Industry 4.0 and IIoT platforms, including:

1. Azure IoT Hub / IoT Edge, AWS IoT, or equivalent platforms.

2. MQTT, OPC UA, edge gateways, and device management.

3. Integration with MES, WMS, ERP, and data historian systems.

• Knowledge of OT cybersecurity concepts such as industrial DMZs, firewalls, VLANs, certificates (X.509), incident response, and disaster recovery.

• Programming or scripting experience with Visual Basic, Python, Ignition, SQL, and MQTT.

• Demonstrated experience developing HMI and SCADA systems for production equipment and manufacturing operations.

• Hands-on experience integrating and supporting industrial robotics (e.g., Fanuc, ABB, KUKA, or equivalent).

• Strong working knowledge of industrial communication protocols such as Ethernet/IP, Profibus/Profinet, Modbus, and OPC UA.

• Demonstrated ability to lead controls projects, make independent technical decisions, and provide technical direction to engineers and technicians.

• Ability to troubleshoot complex, cross-discipline issues involving controls hardware, software, networks, and mechanical systems.

• Strong written and verbal communication skills with the ability to clearly explain technical concepts to non-technical stakeholders.

• Ability to work effectively in a manufacturing environment, including on the plant floor during installations, startups, and troubleshooting events.

EDUCATION/EXPERIENCE:

1. Bachelor’s degree in Electrical/Controls/Automation Engineering strongly preferred (or equivalent education/experience).

2. 10+ years of experience in control related field.

3. Demonstrated experience developing HMI and SCADA systems for production equipment and manufacturing operations.

4. Hands-on experience integrating and supporting industrial robotics (e.g., Fanuc, ABB, KUKA, or equivalent).

5. Strong working knowledge of industrial communication protocols such as EtherNet/IP, Profibus/Profinet, Modbus, and OPC UA.

6. Demonstrated ability to lead controls projects, make independent technical decisions, and provide technical direction to engineers and technicians.

7. Ability to troubleshoot complex, cross-discipline issues involving controls hardware, software, networks, and mechanical systems.

8. Strong written and verbal communication skills with the ability to clearly explain technical concepts to non-technical stakeholders.

9. Ability to work effectively in a manufacturing environment, including on the plant floor during installations, startups, and troubleshooting events.