Senior Controls

2 weeks ago

Dallas, United States Kensington Additive Full time

Could also be based in San FranciscoSummaryWe are seeking a highly skilled Senior Controls & Automation Engineer to lead the implementation, integration, and security hardening of advanced PLC/SCADA systems within next-generation automated manufacturing environments. This role focuses on PLC programming, SCADA integration, FAT/SAT execution, industrial networking, and cross-functional automation coordination, supporting the launch of high-performance automated production lines. Ideal for engineers experienced in Rockwell, EtherNet/IP, Ignition, and MES/SCADA connectivity who want to work in a cutting-edge, software-driven manufacturing setting.Hiring at Senior level, with flexibility for Staff/Lead for exceptional applicants.Key ResponsibilitiesCommission and Launch New Automated Manufacturing Lines• Deploy PLC programming assets (AOIs, UDTs, custom routines) onto production equipment.• Ensure full MES–SCADA integration with all automated machinery.• Troubleshoot PLC logic, telemetry, machine-tasking issues, and automation faults during commissioning.• Own and maintain FAT/SAT checklists, test plans, and software validation procedures.Implement High-Quality Controls Engineering and Security Standards• Contribute to structured PLC code development using Git, CI/CD, and automated testing workflows.• Diagnose and resolve EtherNet/IP, OPC-UA, protocol, and industrial networking issues using tools such as Wireshark and protocol analyzers.• Implement CMMC/NIST-aligned controls: secure user roles, segmentation, CIP Security, OPC-UA certificates, audit logging, patching, and backup/restore protocols.Enforce Controls & Automation Standards• Guide vendors and integrators on correct application of internal PLC/HMI standards and integration rules.• Review, test, and refactor PLC programming artifacts to ensure scalability and maintainability.• Drive outstanding issues to closure during commissioning and operational ramp-up.Collaborate Across Robotics, Automation, Manufacturing & Software Teams• Work closely with MES engineers to support a fully software-driven factory model.• Partner with robotics and automation teams to test new control features, refine PLC artifacts, and gather operator/manufacturing feedback.• Support cross-functional troubleshooting, change requests, and documentation updates.Minimum RequirementsPLC Programming & Automation Experience• 2–5 years of experience programming PLCs and HMIs in manufacturing, material handling, robotics, or general automation.• Strong understanding of Rockwell Studio 5000, FactoryTalk View, AOI/UDT development, EtherNet/IP, and industrial networks.• Demonstrated SCADA integration experience (Ignition, FactoryTalk Optix, AVEVA Edge, etc.).Software Engineering Skills (Highly Valued)• Proficiency in Go or Python for testing, automation, data collection, and troubleshooting.• Familiarity with Git workflows, semantic versioning, code reviews, CI pipelines, automated testing, and technical documentation.Collaborative Engineering Background• Experience executing FAT/SAT processes, resolving programming requirements, and driving acceptance criteria to completion.• Ability to interpret specifications, manage change requests, and coordinate across multidisciplinary teams.• Excellent written and verbal communication skills.Willingness to Deliver• Travel up to 25% for vendor testing, site commissioning, and integration work.

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