Senior Controls Engineer

Senior Controls Engineer

Title: Senior Controls Engineer

Title: Birmingham, AL

Salary: $140,000 - $150,000

Founded in 1999, this privately-held industrial automation and systems integration organization employs approximately 30-50 employees, with the majority of its engineering, project management, controls, panel fabrication, and support teams operating from its Birmingham, Alabama headquarters. We specializes in automation integration, robotics, motion control, machine vision, PLC/HMI programming, control panel design and fabrication, conveyance systems, and manufacturing process optimization for industrial clients throughout the United States. Our Birmingham operation serves as the primary engineering and execution hub, supporting the design, programming, commissioning, startup, and lifecycle support of custom automation solutions. Industries served include automotive, metals, manufacturing, consumer products, food and beverage, packaging, engineered products, and other industrial production environments.

Position Overview
 

We are seeking a Senior Controls Engineer to lead the design, implementation, and commissioning of industrial control systems for process and manufacturing applications. The successful candidate will be responsible for architecture, programming, integration, and validation of PLC/HMI/SCADA systems, motion control and drives, and instrumentation. This role serves as a technical lead and mentor, driving best practices for control system development, functional safety, and system reliability while coordinating with multidisciplinary engineering, project managers, vendors, and clients.

Key Responsibilities

• Lead design, development and deployment of PLC, HMI and SCADA control systems for new and retrofit projects.
• Program and maintain controllers across multiple platforms (Allen-Bradley/Rockwell, Siemens, Schneider, Mitsubishi, Honeywell) using IEC 61131-3 languages: Ladder Logic, Structured Text, Function Block Diagram and other vendor-specific tools.
• Architect and implement control strategies, control loops and PID tuning, and apply control theory and loop design best practices.
• Design and commission VFDs, motor control, servo and motion control systems, including tuning and performance validation.
• Specify and interpret P&IDs, instrumentation diagrams and I/O lists; select sensors and field devices including thermocouples, transmitters and actuators.
• Develop industrial network architectures and configure communications using Profibus, Profinet, Ethernet/IP, OPC/UA and MQTT; ensure secure and reliable data exchange with SCADA and enterprise systems.
• Prepare electrical panel designs, wiring schematics and AutoCAD Electrical drawings; oversee panel fabrication and wiring quality.
• Plan and execute FAT, SAT and on-site commissioning activities; perform system integration, start-up support and detailed troubleshooting.
• Implement and validate functional safety requirements (SIL assessments, safety lifecycle) in accordance with IEC 61508/61511 where applicable.
• Create and maintain clear documentation: functional specifications, control narratives, test plans, commissioning reports and SOPs.
• Use Matlab/Simulink and controls modeling tools for simulation, algorithm development and performance verification.
• Mentor and coach junior controls engineers and technicians; provide technical leadership and review code, design and test results.
• Collaborate with project managers, mechanical and electrical teams, vendors and clients to deliver projects on schedule and within budget.
• Drive continuous improvement by establishing standards, reusable libraries, code templates and engineering best practices.

Qualifications

• Bachelors degree in Electrical Engineering, Control Systems, Mechatronics or a related engineering discipline (Masters preferred).
• 7+ years of hands-on experience in industrial controls engineering, programming and commissioning. Senior-level experience across multiple industries preferred.
• Proven programming and implementation experience with PLCs and HMIs; familiarity with Allen-Bradley/Rockwell, Siemens, Schneider, Mitsubishi and Honeywell platforms.
• Strong knowledge of IEC 61131-3 languages (Ladder, Structured Text, Function Block Diagram) and control design fundamentals including PID tuning and control theory.
• Experience with industrial networks and protocols: Profibus, Profinet, Ethernet/IP, OPC/UA and MQTT.
• Experience with VFDs, motor control, servo/motion control systems and associated drives.
• Practical experience with instrumentation, thermocouples, P&IDs, electrical panel design and AutoCAD Electrical.
• Experience planning and executing FAT/SAT and site commissioning, system integration and complex troubleshooting.
• Working knowledge of functional safety standards (SIL, IEC 61508/61511) and experience implementing safety-related systems.
• Familiarity with SCADA platforms and tools (Ignition preferred), OPC connectivity and HMI design best practices.
• Experience with Matlab/Simulink or equivalent simulation tools for controls modeling and verification.
• Strong communication, project leadership and documentation skills; proven ability to work with cross-functional teams and mentor junior staff.
• Professional certifications a plus: Rockwell or Siemens training, ISA/functional safety certification, PMP or equivalent project management credential.

Benefits

- For this position, you must be currently authorized to work in the United States without the need for sponsorship for a non-immigrant visa. This job was first posted by CyberCoders on 10/30/2026 and applications will be accepted on an ongoing basis until the position is filled or closed.Everforth CyberCoders is proud to be an Equal Opportunity Employer

All qualified applicants will receive consideration for employment without regard to race, color, religion, sex, age, sexual orientation, gender identity or expression, national origin, ancestry, citizenship, genetic information, registered domestic partner status, marital status, status as a crime victim, disability, protected veteran status, or any other characteristic protected by law. Our hiring process includes AI screening for keywords and minimum qualifications, and a virtual recruiter as part of the application process. A human recruiter reviews all results. Click here for details on our virtual recruiter .  Everforth CyberCoders will consider qualified applicants with criminal histories in a manner consistent with the requirements of applicable state and local law, including but not limited to the Los Angeles County Fair Chance Ordinance, the San Francisco Fair Chance Ordinance, and the California Fair Chance Act. Everforth CyberCoders is committed to working with and providing reasonable accommodation to individuals with physical and mental disabilities. Individuals needing special assistance or an accommodation while seeking employment can contact a member of our Human Resources team at Benefits@CyberCoders.com to make arrangements.

Salary

$140000 - $150000 USD per year