Senior Controls Engineer

Job Description

Quest Global delivers world-class end-to-end engineering solutions by leveraging our deep industry knowledge and digital expertise. By bringing together technologies and industries, alongside the contributions of diverse individuals and their areas of expertise, we are able to solve problems better, faster. This multi-dimensional approach enables us to solve the most critical and large-scale challenges across the aerospace & defense, automotive, energy, hi-tech, healthcare, medical devices, rail and semiconductor industries.

We are looking for humble geniuses, who believe that engineering has the potential to make the impossible possible; innovators, who are not only inspired by technology and innovation, but also perpetually driven to design, develop, and test as a trusted partner for Fortune 500 customers. As a team of remarkably diverse engineers, we recognize that what we are really engineering is a brighter future for us all. If you want to contribute to meaningful work and be part of an organization that truly believes when you win, we all win, and when you fail, we all learn, then we’re eager to hear from you.

The achievers and courageous challenge-crushers we seek, have the following characteristics and skills:

We are seeking an experienced Senior Controls Engineer to lead the commissioning, startup, testing, and validation of automated material handling and warehouse control systems.

The ideal candidate will have extensive experience with PLCs, HMI/SCADA systems, industrial networks, commissioning activities, troubleshooting, and customer-facing project execution.

This role requires close collaboration with controls design, software development, project management, field service teams, and customers to ensure successful project delivery while meeting safety, quality, schedule, and performance requirements.

What You will Do:

• Perform on-site project commissioning of material handling logistics systems that integrate mechatronic hardware and software to deliver an automated customer solution primarily based on convey/sort technologies
• Troubleshooting PLC and Hardware-Related Issues
• Seek advice and guidance from others on non-routine or more complex equipment and areas of the system
• Identify problems as they occur and take appropriate steps to solve them
• Provide assistance in recommending ideas related to productivity improvement, cost reduction and improvement in customer satisfaction
• Provide regular Commissioning status/progress updates to leadership
• Support on-site Reliability, Performance, and Volume Testing, System Start-up, Go-Live, and post Go-Live customer support for projects
• Travel approximately 80% to different Customer locations with in US

Commissioning & Startup

• Lead controls commissioning activities for automated warehouse and material handling systems.
• Perform PLC, HMI, VFD, servo, scanner, and field device checkout.
• Execute startup procedures and system bring-up activities.
• Validate control system functionality against design specifications.
• Conduct subsystem and integrated system testing.
• Test and validate PLC programs, HMI applications, and control sequences.
• Verify electrical and controls installations.
• Perform I/O checkout and field device verification.
• Support software integration between:
• • PLCs
  • Warehouse Control Systems (WCS)
  • Warehouse Management Systems (WMS)
  • SCADA systems
  • Third-party equipment
• Diagnose hardware, software, communication, and performance issues.
• Troubleshoot industrial communication protocols.
• Conduct root cause investigations and implement corrective actions.
• Support issue resolution during customer acceptance testing.
• Serve as the primary on-site controls representative.
• Coordinate commissioning activities with customers and subcontractors.
• Provide technical updates to project management.
• Support Site Acceptance Testing (SAT) and go-live activities.
• Deliver operator and maintenance training.
• Create and maintain commissioning reports.
• Track punch-list items and project issues.
• Prepare startup, testing, and validation documentation.
• Review electrical drawings and controls documentation.
• Mentor junior commissioning engineers.
• Provide technical leadership during startup activities.
• Drive commissioning best practices and continuous improvement initiatives

What You Will Bring:

• Bachelor's Degree in Electrical/Controls/Mechatronics/Automation Engineering Related Technical Field
• 8+ years of controls engineering experience.
• Min 5+ years of commissioning experience in industrial automation.
• Experience commissioning large-scale automated warehouse or material handling systems.
• Strong experience in Rockwell Studio 5000 / Allen-Bradley ControlLogix - MUST, Siemens TIA Portal (S7-1500, S7-1200)
• Experience with HMI/SCADA, FactoryTalk View SE/ME, WinCC, Ignition, Wonderware
• Knowledge of EtherNet/IP, Profinet, Modbus TCP/IP, OPC UA, TCP/IP Networking
• Experience in Motion Control like VFDs, Servo systems, Conveyors, ASRS, Sortation systems

Pay Range: $80,000-130,000/year

Compensation decisions are made based on factors including experience, skills, education, and other job-related factors, in accordance with our internal pay structure. We also offer a comprehensive benefits package, including health insurance, paid time off, and retirement plan.

Work Requirements:

Due to the nature of the work, 50-80% of travel is required anywhere in US as per the project requirement.

The candidate appears capable of performing the technical and administrative aspects of the role remotely. However, the position requires 50-80% travel and significant on-site activities. The key consideration is whether the candidate can consistently meet those travel and fieldwork requirements. When travel is not required, the remaining duties can generally be performed remotely.

Travel Requirements:

Due to the nature of the work, 50-80% of travel is required

Ability to work extended hours during startup and go-live periods

Benefits
• 401(k)
• 401(k) matching 
• Dental insurance
• Health insurance
• Life insurance
• Paid time off
• Referral program
• Vision insurance
• Short/Long Term Disability

Who We Are:
Quest Global delivers world-class end-to-end engineering solutions by leveraging our deep industry knowledge and digital expertise. By bringing together technologies and industries, alongside the contributions of diverse individuals and their areas of expertise, we are able to solve problems better, faster. This multi-dimensional approach enables us to solve the most critical and large-scale challenges across the aerospace & defense, automotive, energy, hi-tech, healthcare, medical devices, rail and semiconductor industries.
We are looking for humble geniuses, who believe that engineering has the potential to make the impossible possible; innovators, who are not only inspired by technology and innovation, but also perpetually driven to design, develop, and test as a trusted partner for Fortune 500 customers. As a team of remarkably diverse engineers, we recognize that what we are really engineering is a brighter future for us all. If you want to contribute to meaningful work and be part of an organization that truly believes when you win, we all win, and when you fail, we all learn, then we’re eager to hear from you.

The achievers and courageous challenge-crushers we seek, have the following characteristics and skills: