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Senior Controls Engineer

Principal Accountabilities/ Responsibilities:

  • Accountable for leading the controls engineering for expansions/large capital projects.
  • Work with OEMs, vendors, and contractors to design, install, integrate and start-up new equipment and process controls. This includes selecting and approving electrical and instrumentation components, reviewing, approving electrical and process control network designs, evaluating software, conducting machine acceptance testing and resolving issues.
  • Responsible for specifying Distributed Control Systems (DCS), PLC’s, HMI’s, servo systems, instrumentation, network components and analysis software in accordance with FQT controls standards.
  • Assesses, identifies, schematically designs, and makes complex program modifications in DCS, PLC logic, HMI programs and servo controller logic for production equipment and associated assets. Provides quality checks to insure correct software development.

Qualifications/ education and experience requirements:

(e.g. degrees, certificates of specific trainings)

  • Bachelor’s degree in electrical/controls/ mechanical Engineering, or related field.
  • Minimum 7-10 years of relevant experience with demonstrated results.
  • Focused controls engineering experience including specifying control elements/devices, programming control loops, troubleshooting/optimizing processes.
  • Advanced PLC based hardware and software, Distributed Control Systems, and automation experience.
  • Experience with industrial control networks design, set up and troubleshooting.
  • Execution of large capital projects.
  • Paper experience a plus.
  • Strong communication, analytical and collaboration skills interfacing with all levels of the organization; ability to simplify complex issues and resolve issues.
  • Computer skills including specific controls programming software, email, word processing, spreadsheet applications, and project management software.
  • Prior supervisory experience a plus.
  • Ability to travel to consultant engineering office, vendors, and expansion site. This role will transition to the new expansion site.

Skills requirements:

(e.g., analytical, teamwork, problem solving, ability to use certain equipment, etc.)

  • Problem solving/analytics
  • Communication skills with the ability to engage and drive understanding throughout all levels of the organization
  • Technical Leadership with ability to mentor and lead divisional level technical objectives
  • Basic business ownership skills enabling critical thinking, recommendations, and project justifications. 

Competencies

  • PLC & DCS Programming
  • Large capital expansion/projects execution
  • Influencing without authority
  • Multi-site or central technical support
  • Authoring specifications and best practices

Work Environment (if applicable):

Physical and Other Requirements (if appliable):

  • Apx. 25% travel
  • Ability to relocate to new mid-west site

Direct Reports (if applicable):

  • None

Disclaimer:

The above information on this job description has been described to indicate the general nature and level of work performed by incumbents.  Other duties and responsibilities not specifically described may be assigned from time to time, consistent with knowledge, skills and abilities of the incumbent.

First Quality is committed to protecting information under the care of First Quality Enterprises commensurate with leading industry standards and applicable regulations.  As such, First Quality provides at least annual training regarding data privacy and security to employees who, as a result of their role specifications, may come in to contact with sensitive data.

First Quality is an Equal Opportunity employer. All qualified applicants will receive consideration for employment without regard to race, color, religion, sex, national origin, disability, sexual orientation, gender identification, or protected Veteran status.

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Average salary estimate

$110000 / YEARLY (est.)
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$95000K
$125000K

If an employer mentions a salary or salary range on their job, we display it as an "Employer Estimate". If a job has no salary data, Rise displays an estimate if available.

What You Should Know About Senior Controls Engineer, First Quality

At First Quality, we're seeking a talented Senior Controls Engineer to join our team in Defiance, OH. This key position involves spearheading the controls engineering initiatives for our larger capital projects and expansions. You’ll be at the forefront of designing and integrating new equipment and process controls, collaborating closely with OEMs, vendors, and contractors. Your expertise in selecting electrical and instrumentation components while ensuring compliance with FQT controls standards will be crucial. You’ll also handle everything from specifying Distributed Control Systems (DCS), PLCs, and HMIs, to conducting rigorous machine acceptance testing. With over 7-10 years of controls engineering experience, you’ll utilize your advanced knowledge in PLC-based systems to assess and enhance production equipment. This role is not just about managing tasks; it's about mentoring junior engineers, solving complex issues, and providing technical leadership that drives project success. If you're ready to take your career to the next level in an environment that values innovation and collaboration, we’d love to hear from you!

Frequently Asked Questions (FAQs) for Senior Controls Engineer Role at First Quality
What are the primary responsibilities of a Senior Controls Engineer at First Quality?

The Senior Controls Engineer at First Quality is accountable for leading the engineering of controls for large capital projects and expansions. Responsibilities include designing and integrating new equipment, selecting electrical components, specifying Distributed Control Systems, conducting machine acceptance testing, and resolving issues throughout the process.

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What qualifications do I need to apply for the Senior Controls Engineer position at First Quality?

To qualify for the Senior Controls Engineer role at First Quality, candidates should have a bachelor's degree in electrical, mechanical, or controls engineering, alongside a minimum of 7-10 years of relevant experience. Skills in PLC programming, DCS systems, and project management are essential.

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What technical skills are important for a Senior Controls Engineer at First Quality?

A Senior Controls Engineer at First Quality should possess advanced skills in PLC and DCS programming, experience with industrial control networks design, automation, along with strong analytical and problem-solving abilities. Communication skills are vital as well, as this role involves collaboration with various teams.

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How much travel is involved in the Senior Controls Engineer position at First Quality?

The Senior Controls Engineer position at First Quality involves approximately 25% travel, particularly to engineering offices, vendor locations, and expansion sites as part of the job responsibilities.

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What kind of projects will a Senior Controls Engineer work on at First Quality?

As a Senior Controls Engineer at First Quality, you will primarily work on large capital projects and expansions, focusing on the design, integration, and optimization of process controls and instrumentation to enhance production capabilities.

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Common Interview Questions for Senior Controls Engineer
How do you approach troubleshooting an industrial control system?

In troubleshooting an industrial control system, it's important to methodically analyze the system’s architecture. Begin with a clear understanding of the controls and processes involved, check for any recent changes, and review the documentation. Utilize diagnostic tools and be prepared to isolate the issue by testing components individually.

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Can you describe your experience with PLC and DCS programming?

My experience with PLC and DCS programming encompasses developing control logic, conducting simulations, and deploying those programs on actual equipment. I ensure thorough testing and quality checks, applied best practices in programming and participated in large-scale implementation projects.

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What project management experience do you have related to capital projects?

I have managed multiple capital projects where I led the planning, execution, and delivery phases. This included scheduling, budget management, stakeholder communication, and ensuring compliance with industry standards while meeting all project objectives.

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How do you prioritize tasks during a project execution?

I prioritize tasks based on project timelines, impact on the project’s success, and available resources. I employ project management tools to visualize task dependencies and ensure timely execution while remaining flexible to adapt to any urgent issues.

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What methods do you use to mentor junior engineers?

To mentor junior engineers, I encourage hands-on learning and provide them with opportunities to take on challenging tasks. Regular feedback sessions, collaborative projects, and sharing knowledge through training workshops can greatly enhance their skills and confidence.

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Describe a time you resolved a significant issue in a control system.

In a previous role, we encountered a recurring fault in a control system that caused downtime. I conducted a detailed analysis, identified a faulty sensor, and upon replacement, implemented a secondary monitoring mechanism to prevent future occurrences, resulting in improved system reliability.

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How do you stay updated on advancements in control systems technology?

I stay updated by attending industry conferences, participating in professional organizations, and following leading technology publications. Continuous learning through online courses and webinars also enhances my knowledge of current trends and innovations in control systems.

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What challenges do you anticipate in the Senior Controls Engineer role at First Quality?

Anticipated challenges include adapting to rapidly changing technologies and managing stakeholder expectations during complex projects. I believe strong communication and a proactive approach are essential to overcome these obstacles and ensure successful project outcomes.

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How do you measure the success of a control system you’ve implemented?

I measure the success of a control system through key performance indicators such as system uptime, accuracy of control processes, and overall efficiency in production output. Gathering feedback from operators and stakeholders aids in evaluating the effectiveness post-implementation.

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What is your leadership style as it pertains to technical teams?

My leadership style is collaborative and supportive. I focus on empowering my team members by encouraging them to share ideas and take ownership of their work. Providing guidance while allowing autonomy builds a motivated and innovative engineering environment.

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First Quality was founded in 1989 and has grown to be a global privately held company with over 4,000 employees. Its corporate offices are located in Great Neck, New York, with manufacturing facilities and offices in Pennsylvania, South Carolina, ...

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Full-time, on-site
DATE POSTED
April 22, 2025

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