Senior Controls & Automation Engineer

Polaris Automation is an employee-owned smart manufacturing partner delivering automation and controls solutions to manufacturers. The Senior Controls & Automation Engineer leads controls design, PLC/HMI programming, and on-site project execution, while providing technical leadership and mentorship to engineering teams.

Responsibilities

Independently design, develop, troubleshoot, and implement PLC and HMI applications, with a strong focus on Rockwell/Allen-Bradley platforms

Develop complex PLC logic using Ladder Logic and Function Block programming within Studio 5000

Design and implement reusable, scalable PLC code using User-Defined Data Types (UDTs) and Add-On Instructions (AOIs)

Develop and troubleshoot equipment interlocks, permissives, and sequencing logic to support safe, reliable system operation

Support the development of controls solutions for complex manufacturing processes, including batch and recipe-based applications

Interpret customer specifications, electrical drawings, and functional requirements to develop effective controls solutions

Generate, review, and validate engineering drawings, PLC code, HMI applications, and technical documentation

Lead troubleshooting, testing, installation, startup, and commissioning activities at customer facilities

Serve as the senior technical resource on assigned projects, providing technical direction and ensuring engineering deliverables meet project requirements

Establish design schedules, milestones, and technical priorities in collaboration with the project team

Lead technical design reviews and identify potential engineering challenges early

Review PLC code, HMI applications, engineering drawings, and documentation developed by other engineers

Provide mentorship and technical guidance to Controls Engineers and Project Engineers on programming standards, design approaches, and troubleshooting

Collaborate with project teams to estimate engineering hours, manage technical scope, and support delivery within budget

Communicate project risks, technical issues, and scope changes clearly to internal teams and customers

Participate in customer kickoff meetings, design reviews, and project closeout activities

Oversee control panel fabrication as needed to ensure quality and design accuracy

Support project bids and proposals by providing technical input on solution design, scope, and engineering estimates

Provide occasional after-hours support when project needs require it

Preferred

Experience designing or implementing batch processing and recipe management systems

Experience with Rockwell PlantPAx distributed control systems, including PlantPAx objects

Familiarity with Rockwell FactoryTalk software and HMI/SCADA development

Experience with additional PLC platforms, such as Siemens

Experience developing standardized PLC code libraries or reusable automation solutions

Experience mentoring or guiding less experienced controls engineers

Background supporting project bids, technical estimates, and proposal development

Experience integrating PLC control systems with SCADA, MES, or other manufacturing software

Batch Processing Systems

Recipe Management Systems

Rockwell PlantPAx DCS

PlantPAx Objects

Rockwell FactoryTalk

HMI/SCADA Development

PLC Platforms

Siemens PLCs

Standardized PLC Code Libraries

Reusable Automation Solutions

Controls Engineering

Project Bid Support

Technical Estimating

Proposal Development

PLC System Integration

SCADA Integration

MES Integration

Manufacturing Software Integration

Mentoring

Guiding Engineers

Benefits

Medical, dental, and vision insurance (day 1)

Company-funded Health Reimbursement Account (HRA)

Employee Stock Ownership Plan (ESOP)

401(k) with company match

Company-paid life insurance

Paid parental leave

Flexible remote schedule

Generous PTO and paid holidays

Wellness programs and gym membership reimbursement

Mental health and wellbeing benefits

Company

Manufacturing automation and MES solutions

Columbus, Ohio, USA

https://www.polarisautomation.com/

Founded in 1984

51-200 employees

Qualifications

Bachelor's degree in Electrical Engineering, Controls & Automation Engineering, or a related field, or equivalent practical experience

Minimum 8 years of professional controls and automation engineering experience

Strong, hands-on experience programming Rockwell/Allen-Bradley PLCs using Studio 5000

Advanced proficiency in Ladder Logic and Function Block programming

Demonstrated experience developing structured, reusable PLC code using User-Defined Data Types (UDTs) and Add-On Instructions (AOIs)

Strong understanding of interlocks, permissives, equipment sequencing, and complex control logic

Proven ability to independently develop, troubleshoot, and commission PLC applications from the ground up

Experience developing and troubleshooting HMI applications

Ability to interpret electrical drawings, customer specifications, and functional design requirements

Experience providing technical leadership or serving as the lead engineer on controls projects

Strong troubleshooting skills and the ability to solve complex automation challenges independently

Clear communication skills and the ability to collaborate effectively with customers, engineers, and project teams

Willingness to travel to customer facilities for installation, startup, and commissioning

Experience designing or implementing batch processing and recipe management systems

Experience with Rockwell PlantPAx distributed control systems, including PlantPAx objects

Familiarity with Rockwell FactoryTalk software and HMI/SCADA development

Experience with additional PLC platforms, such as Siemens

Experience developing standardized PLC code libraries or reusable automation solutions

Experience mentoring or guiding less experienced controls engineers

Background supporting project bids, technical estimates, and proposal development

Experience integrating PLC control systems with SCADA, MES, or other manufacturing software

Minimum 8 years of professional controls and automation engineering experience.

Required skills

Rockwell/Allen-Bradley PLC Programming, Studio 5000, Ladder Logic, Function Block Programming, User-Defined Data Types (UDTs), Add-On Instructions (AOIs), Interlocks, Permissives, and Equipment Sequencing, HMI Development, PLC Commissioning, Technical Project Leadership, Batch Processing and Recipe Management, Rockwell PlantPAx

Preferred skills

Experience with additional PLC platforms, such as Siemens

Experience

8+ years