Senior Controls Engineer

Talon Hiring Solutions has a client, in the greater Birmingham, AL area seeking a Senior Controls Engineer to join the team. This individual will provide technical leadership in the design, programming, integration, and commissioning of complex automation and robotic systems. The role combines advanced controls engineering expertise with project oversight, team leadership, and process improvement. The ideal candidate has extensive experience with industrial automation, a strong understanding of electrical and control system design, and a proven ability to lead complex projects while mentoring engineers and technicians. This is an opportunity to drive technical innovation, improve engineering processes, and deliver high-quality automation solutions.

What You’ll Do

• Lead the design, development, programming, and integration of complex automation and control systems, including electrical schematics, control panel layouts, and PLC/HMI programming.
• Develop advanced automation solutions involving multi-system integration, safety interlocks, legacy system upgrades, and large-scale automation strategies.
• Establish and maintain standards for control system hardware, software, system architecture, and programming practices.
• Validate and optimize system functionality through simulation, testing, commissioning, and on-site troubleshooting.
• Serve as the lead controls engineer on key projects, overseeing execution from initial design through installation and deployment.
• Define project scope, lead design reviews, make technical decisions, and resolve complex engineering challenges.
• Manage project schedules, cost estimates, resource allocation, and milestones to support on-time, on-budget delivery.
• Collaborate with mechanical, electrical, and applications engineering teams to ensure seamless system integration and effective project execution.
• Supervise, mentor, and develop Controls Engineers and Technicians by assigning work, reviewing technical deliverables, and providing constructive feedback.
• Identify training needs and implement development opportunities, including technical workshops, job shadowing, and one-on-one coaching.
• Promote knowledge sharing, document best practices, and encourage accountability, collaboration, and technical excellence across the department.
• Develop and maintain engineering standards, reusable code libraries, design templates, and checklists to improve consistency and efficiency.
• Identify workflow inefficiencies, perform root cause analysis, and implement process improvements to reduce rework and project cycle times.
• Evaluate emerging technologies, including new PLC platforms, industrial IoT solutions, diagnostic tools, and smart instrumentation, to improve system performance and engineering capabilities.
• Ensure control systems comply with applicable electrical codes, OSHA regulations, company safety standards, and relevant machine-safety requirements.
• Review safety-critical designs, including safety PLC logic, emergency stops, risk assessments, lockout/tagout procedures, and machine safeguarding.
• Partner with Health and Safety teams to conduct hazard analyses, support pre-startup safety reviews, and maintain compliance with applicable safety standards.
• Travel to customer facilities as needed to support project execution, commissioning, troubleshooting, and system optimization.

What You’ll Bring

• Bachelor’s degree in Electrical Engineering, Mechatronics, Industrial Automation, or a related field.
• At least 5 years of controls programming or comparable industrial controls experience, including a minimum of 3 years leading complex, multidisciplinary automation projects from design through commissioning.
• Demonstrated success managing both the technical and operational aspects of large-scale control system deployments.
• Extensive hands-on experience programming, integrating, and troubleshooting PLCs, HMIs, variable frequency drives (VFDs), servos, robots, and other industrial control systems.
• Experience with PLC platforms such as Allen-Bradley, Omron, Siemens, GE, or similar systems.
• Strong ability to read and interpret electrical schematics, technical drawings, and print sets.
• Experience designing and developing electrical prints is preferred.
• Experience with robotic systems, machine vision, and advanced automation technologies.
• Knowledge of applicable electrical codes and industrial safety requirements, including NEC, IEC, OSHA, machine safeguarding, and functional safety concepts such as Safety Integrity Levels (SIL) and Performance Levels (PL).
• Proven leadership skills, including the ability to mentor engineers and technicians, review technical work, and support professional development.
• Strong project management, problem-solving, and organizational skills, with the ability to manage competing priorities and meet project deadlines.
• Excellent written and verbal communication skills, including the ability to work effectively with customers, engineering teams, and company leadership.
• Strong computer skills and the ability to maintain accurate technical documentation.
• A self-motivated, results-oriented approach with the ability to make sound technical decisions and work independently.
• Willingness and ability to travel to customer facilities as required.
• A valid U.S. driver’s license and a clean driving record.
• Ability to successfully complete required background checks and pre-employment and random drug screenings.