SENIOR CONTROLS ENGINEER

As a Senior Controls Engineer at ASI, a Division of Livingston & Haven, you will serve as a technical leader and mentor within the Controls Engineering Department. This role is responsible for designing, programming, and supporting automation systems while overseeing project execution and ensuring compliance with company standards. The Senior Controls Engineer plays a pivotal part in supervising, mentoring, and developing both Controls Engineers and Technicians while also driving innovation, efficiency, and project success.

• Primary Responsibilities include but are not limited to:
  • Technical Leadership
    • Lead complex controls system designs, including electrical schematics, panel layouts, and PLC/HMI programming.
    • Develop and implement advanced automation solutions requiring high-level design, integration, and troubleshooting expertise.
    • Drive system architecture discussions and standardization efforts for hardware and software.
    • Validate and optimize system functionality and performance through simulation and on-site testing.
    • Take ownership of the most technically challenging and mission-critical design tasks that go beyond the scope assigned to Controls Engineers. While Controls Engineers may assist with component layouts and mid-level system development, Senior Controls Engineers are expected to manage high-stakes designs involving multi-system integration, safety interlocks, legacy system upgrades, and large-scale automation strategies.
  • Project Oversight
    • Serve as lead controls engineers on key and technically complex projects, managing all phases from design to deployment. This includes defining project scope, leading design reviews, and serving as the primary decision-maker for all control-related technical matters.
    • Oversee and actively manage project timelines, cost estimates, labor allocation, and milestone tracking to ensure successful delivery within scope and budget constraints. Escalate and resolve issues quickly to minimize project disruption.
    • Coordinate closely with mechanical, electrical, and applications engineering teams to ensure all aspects of the system work cohesively. Represent the controls function in project meetings and drive alignment across all technical disciplines. Provide guidance and feedback to improve integration across departments.
  • Associate Development
    • Directly supervise Controls Engineers and Technicians, assigning technical and developmental tasks, reviewing work quality and technical accuracy, and providing in-depth, constructive feedback tailored to each team member’s growth path.
    • Identify skill gaps through formal assessments, peer reviews, and project debriefs. Develop and implement structured training programs, including technical workshops, job shadowing, and one-on-one coaching, to ensure continuous improvement and team advancement.
    • Facilitate structured knowledge-sharing sessions, document best practices, and ensure dissemination of technical lessons learned across the department. Champion a culture of mentorship, accountability, and technical excellence.
  • Process Improvement
    • Develop, document, and refine comprehensive engineering standards, code libraries, design templates, and checklists to ensure consistency and efficiency across all controls projects. Ensure all materials are regularly reviewed and updated to reflect industry best practices and lessons learned from past projects.
    • Lead department-wide initiatives to optimize workflows and reduce project cycle time. Analyze engineering bottlenecks and inefficiencies through data tracking, conduct root cause analysis, and implement corrective strategies. Monitor KPIs such as rework rates, on-time delivery, and engineering hours per project to drive continuous improvement.
    • Research, test, and implement cutting-edge technologies such as emerging PLC platforms, industrial IoT, advanced diagnostic tools, and smart instrumentation. Conduct pilot programs and technical evaluations, lead vendor collaboration meetings, and deliver departmental training on adopted tools and practices to ensure smooth implementation and maximum value.
  • Safety & Compliance
    • Ensure strict adherence to national and international electrical codes (e.g., NEC, IEC), OSHA safety regulations, and all internal ASI safety protocols. Serve as a subject matter expert for interpreting and applying these standards to all controls projects.
    • Conduct thorough reviews and audits of safety-critical components, including detailed evaluations of risk assessments, safety PLC logic, emergency stop configurations, lockout/tagout (LOTO) procedures, and machine safeguarding implementations. Ensure designs meet or exceed required safety integrity levels (SIL/PL).
    • Collaborate with the Health and Safety team to lead hazard analyses and facilitate pre-startup safety reviews (PSSRs) for automation systems.
    • Stay current with evolving safety legislation and recommend updates to departmental processes to ensure ongoing compliance and best-in-class safety practices.