Senior Controls Engineer

Job Title: Senior Controls EngineerJob Description

The Senior Controls Engineer will design, program, install, and maintain industrial automation and control systems, including PLCs, SCADA platforms, robotics, and related technologies. This role supports the integration of AI-driven solutions into manufacturing operations, enabling predictive maintenance, real-time decision making, adaptive automation, and continuous process optimization. The ideal candidate combines strong technical expertise with a systems-thinking mindset and a passion for driving operational excellence.

Responsibilities

• Design, develop, program, and maintain PLC, HMI, SCADA, DCS, robotics, and industrial networking systems.
• Integrate AI and machine learning outputs into automation platforms to support predictive maintenance, anomaly detection, and adaptive process control.
• Troubleshoot and optimize existing manufacturing automation systems to improve reliability, efficiency, and performance.
• Support implementation of Industry 4.0 initiatives, including data collection, analytics, edge computing, and smart manufacturing technologies.
• Lead automation improvement projects focused on productivity, quality, safety, and process consistency.
• Collaborate with operations, maintenance, engineering, and leadership teams to identify and implement system enhancements.
• Develop and maintain control system documentation, standards, and best practices.
• Evaluate new technologies and recommend scalable automation solutions.
• Analyze operational data to identify trends, resolve issues, and drive continuous improvement initiatives.
• Serve as a technical resource for controls, automation, and AI-enabled manufacturing systems.

Essential Skills

• Strong analytical and problem-solving skills with the ability to interpret and leverage data for decision-making.
• Systems-thinking approach with the ability to understand impacts across multiple processes and functions.
• Hands-on experience designing, programming, commissioning, and supporting industrial automation systems.
• Continuous improvement mindset focused on optimization, standardization, and operational efficiency.
• Ability to anticipate technical challenges and proactively implement solutions.
• Experience establishing and supporting best practices for controls architecture and automation design.
• Strong communication and collaboration skills with the ability to influence stakeholders across all levels of the organization.
• Ability to prioritize effectively in fast-paced manufacturing environments and respond to critical issues when needed.
• Proven track record of building relationships with production, maintenance, and engineering teams.

Additional Skills & Qualifications

• Bachelor's degree in Electrical Engineering, Controls Engineering, Automation Engineering, or a related field.
• Minimum of 3 years of controls or automation engineering experience within a manufacturing environment.
• Experience programming and troubleshooting PLC-based control systems.
• Authorization to work in the United States without current or future sponsorship requirements.
• Experience with Allen-Bradley and/or Siemens PLC platforms.
• Strong HMI, SCADA, industrial networking, and communication protocol experience.
• Experience with robotics integration and automated manufacturing systems.
• Exposure to Python, machine learning applications, AI-enabled automation, or edge computing technologies.
• 3+ years of hands-on automation engineering experience supporting manufacturing operations.
• Knowledge of Industry 4.0 technologies, data collection platforms, and predictive maintenance strategies.

Work Environment

The work environment involves fast-paced manufacturing settings where the ability to respond to critical issues is essential. The role requires collaboration with various teams, including operations, maintenance, and engineering, to drive system enhancements and process optimizations.

Job Type & Location

This is a Permanent position based out of Whitehall, MI.

Pay and Benefits

The pay range for this position is $90000.00 - $120000.00/yr.

Individual compensation offered for this position within this range will depend on many factors, including qualifications, skills, relevant experience, job knowledge, geographic location, internal equity, and other pertinent job-related factors.

Strong benefits package, with publicly reported offerings that include: Medical, dental, and vision insurance 401(k) retirement plan Life and disability insurance Employee Assistance Program (EAP) PTO and paid holidays Tuition assistance and training opportunities Parental/adoption benefits (availability can vary by position/location

Workplace Type

This is a fully onsite position in Whitehall,MI.

Application Deadline

This position is anticipated to close on Sep 7, 2026.

About Actalent

Actalent is a global leader in engineering and sciences services and talent solutions. We help visionary companies advance their engineering and science initiatives through access to specialized experts who drive scale, innovation and speed to market. With a network of almost 20,000 consultants and 5,000 clients across the U.S., Canada, Asia and Europe, Actalent serves many of the Fortune 500. We are proud to be an Engineering News-Record (ENR) Top 500 Design Firm for our engineering design services and a ClearlyRated Best of Staffing winner for both client and talent service.

The company is an equal opportunity employer and will consider all applications without regard to race, sex, age, color, religion, national origin, veteran status, disability, sexual orientation, gender identity, genetic information or any characteristic protected by law.

If you would like to request a reasonable accommodation, such as the modification or adjustment of the job application process or interviewing process due to a disability, please email actalentaccommodation@actalentservices.com for other accommodation options.

San Francisco Fair Chance Ordinance: Pursuant to the San Francisco Fair Chance Ordinance, for all positions located in the city and county of San Francisco, we will consider for employment qualified applicants with arrest and conviction records.

Massachusetts Lie Detector: It is unlawful in Massachusetts to require or administer a lie detector test as a condition of employment or continued employment. An employer who violates this law shall be subject to criminal penalties and civil liability.

Use of Artificial Intelligence (AI): We may use Artificial Intelligence (AI) to support parts of our hiring process, including sourcing, screening, and evaluating candidates. AI helps assess applications and qualifications, but final decisions are made by our hiring team. By applying, you acknowledge and agree that your application may be reviewed using AI tools.