SENIOR CONTROLS ENGINEER SKILLS, EXPERIENCE, AND JOB REQUIREMENTS
Updated: Jan 01, 2025 - The Senior Controls Engineer possesses a strong foundation in both electrical/electronics and mechanical systems, with expertise in control strategy development, modeling systems using tools like MATLAB/Simulink, and developing control systems such as mechatronic actuation. This role requires experience with auto-coding of embedded control systems, commissioning control systems, and working on automotive electric vehicle projects, alongside a working knowledge of control theory and system engineering processes. The engineer also has proficiency in CAD software for control layout design, familiarity with Functional Safety standards, and experience in test and validation activities.
Essential Hard and Soft Skills for a Standout Senior Controls Engineer Resume
- PLC Programming
- SCADA Systems
- Control System Design
- Electrical Engineering
- Instrumentation
- Automation Systems
- HMI Development
- Troubleshooting and Diagnostics
- Process Control
- Industrial Communication Protocols
- Problem-Solving
- Project Management
- Communication
- Leadership
- Team Collaboration
- Time Management
- Adaptability
- Critical Thinking
- Decision Making
- Conflict Resolution
Summary of Senior Controls Engineer Knowledge and Qualifications on Resume
1. BS in Mechanical Engineering with 7 years of Experience
- Experience in an electrical/controls engineering capacity in manufacturing environments
- Working knowledge of common electrical systems drawings and documentation, such as electrical plans and elevations, conduit and cable schedules, one-line diagrams, etc.
- Knowledge about programming in different platforms as well as capabilities to troubleshoot any PLC-controlled equipment
- Fault-finding capability on power distribution circuits and production-related equipment
- Controls experience with Allen Bradley and/or other industrial control systems
- Experience with HVAC, compressed air, Purified Water, Dust collection, humidification systems
- Knowledge of cGMP and/or FDA regulatory compliance.
- Working knowledge of CAD, Microsoft Office, and Project Management Software
- Above-average analytical and organizational skills
- Excellent interpersonal and problem-solving skills in a dynamic environment where managing multiple priorities is the norm
- Strong personal leadership skills, good presentation, verbal and written communication skills
- Self-starter and solid team player who is willing to challenge the status quo
2. BS in Electronics Engineering with 8 years of Experience
- Experience in Electrical/Control systems in a relay/PLC-based controls design, development, and implementation in a fast-paced industrial, logistics, production, or manufacturing environment
- Experience directly managing and responsible for multiple large projects
- Operations Management/Distribution Center experience
- Experience in technical leadership for large-scale industrial engineering projects or programs
- Knowledge to communicate with vendors and make decisions using industry-standard knowledge (Controls theory, mechanical/electrical systems, and passive infrastructure).
- Knowledge of Six Sigma analytical and process improvement techniques
- Experience with complex automated material handling equipment, packaging technologies, and systems and manufacturing
- Experience in building relationships with business partners and key stakeholders and experience in working in a cross-functional organization
- Solid written, verbal and interpersonal skills
- Knowledge in hands-on process development and improvement
- Excellent analytical and project management skills
- Experience in leading and interacting with cross-functional teams
3. BS in Control Systems Engineering with 6 years of Experience
- Experience with automation and control systems design, as we as as Electrical Troubleshooting experience
- Proficiency working with common PLC software such as Siemens, Rockwell, Schneider, Modicon, Beckhoff, Codesys, etc
- Proficient in a PLC programming language such as Ladder Logic, Structured Text, Function Block, Sequential Function Charts, etc
- Understanding of mechanical and electrical systems
- Demonstrated ability to plan and execute complex tasks
- Good working knowledge of AutoCAD or SolidWorks, as well as VFD knowledge
- Good working knowledge of HMI systems such as Wonderware, WinCC, FactoryTalk, RSView, Ignition, RedLion, etc
- Experience working with several PLC languages
- Steel plant or equivalent industrial experience
- Understanding of various Fieldbus protocols including Profibus, Profinet, EthernetIP, Modbus, CAN, OPC-UA, etc
- Wonderware HMI, Visual Basic, and SQL programming experience
- Good verbal and written communication skills
4. BS in Computer Engineering with 7 years of Experience
- A broad engineering understanding of either electrical/electronics or mechanical systems (ideally elements of both).
- Experience in control strategy development and modeling systems (e.g. MATLAB/Simulink).
- Experience developing control systems (e.g. eMachine, mechatronic actuation, etc.).
- Working knowledge of control theory.
- Experience in test and validation activities.
- Experience with auto-coding of embedded control systems.
- Experience commissioning control systems on the rig or end applications.
- Knowledge of system engineering processes/tools would be useful (e.g. FMEA, FTA, etc.).
- Relevant experience in software development.
- Experience working on automotive electric vehicle projects
- Experience with CAD software (AutoCAD, etc.) to work with control layout design and schematics
- Knowledge with Functional Safety standards (IEC 62061, IEC 13849, or IEC 61508)
5. BS in Systems Engineering with 9 years of Experience
- Experience in designing and implementing control systems using microcontrollers or PLCs
- Experience building solutions from the ground up, and must be able to do the controller programming himself/herself
- Experience in working with distributed sensor communication.
- Skills and experience in writing own software to test and troubleshoot control systems.
- Willingness to learn new programming languages, new controller architectures, and new skill sets for control system development.
- Ability to manage R&D projects involving multiple stakeholders
- Ability to work in a fast-paced, smaller company environment.
- Experience in designing control systems for solar trackers.
- Experience in developing motion control applications using DC or AC motors.
- Experience in programming Siemens S7 1200 PLCs
- Python and C/C++/C# programming skills.
- Working knowledge of the Linux operating system with experience in using Linux-based edge devices for a distributed sensor application
6. BS in Automation Engineering with 10 years of Experience
- Experience in a fast-paced manufacturing environment with relevant control area
- Experience programming, manipulating, and troubleshooting PLC and HMI programs (Allen Bradley/Siemens platform), especially utilizing Allen Bradley RSLogix Studio 5000, FactoryTalk and AutoCAD Electrical drawing package
- Experience installation of the production line machinery, commissioning and performing acceptance tests
- Experience in the design, development, and troubleshooting of vision inspection systems (Cognex/Keyence).
- Experience in the design and use of data acquisition systems and real-time automation.
- Proficiency in the setup, programming, and manipulation of databases using SQL servers as well as Rockwell
- Experience with electrical, electro-pneumatic and machine guarding safety standards.
- Experience in the application of machine motion controls (torque, speed, position), and servo mechanism
- Experience in the use of LabVIEW software including setup, programming and troubleshooting of the software and programs
- Experience developing, installing and maintaining pneumatic and electro-pneumatic systems.
- Experience with medical device manufacturing environment
- Knowledge of Microsoft Office products including Excel, Project and Outlook