The role of an Automation Controls Engineer is critical in today’s manufacturing and industrial sectors. These professionals are responsible for designing, implementing, and maintaining automation systems that improve efficiency and safety in operations.
They work with a variety of technologies, including programmable logic controllers (PLCs), human-machine interfaces (HMIs), and industrial networks. As industries continue to evolve toward greater automation, the demand for skilled Automation Controls Engineers is on the rise.
In this guide, we detail the responsibilities, essential qualifications, and skills required for this position, empowering your recruitment efforts and helping you attract the ideal candidate for your team.
Automation Controls Engineers are tasked with a variety of critical functions, including:
- •Designing and developing automation systems for control processes.
- •Programming and configuring PLCs, HMIs, and other control devices.
- •Troubleshooting and resolving system issues to minimize downtime.
- •Collaborating with cross-functional teams to understand their automation needs.
- •Conducting tests and validations on implemented solutions to ensure efficiency and compliance.
- •Documenting processes, procedures, and system designs for future reference.
- •Training staff on the operation and maintenance of automation systems.
To be successful in the role of Automation Controls Engineer, candidates should possess:
- •A bachelor’s degree in mechanical engineering, electrical engineering, or a related field.
- •Proficiency in programming languages commonly used in automation, such as Ladder Logic, Structured Text, or Function Block.
- •Familiarity with automation hardware and software.
- •Experience with robotics and machine vision systems is advantageous.
- •Strong problem-solving skills and the ability to work under pressure.
- •Excellent communication skills for effective collaboration with team members and stakeholders.
In addition to the qualifications, Automation Controls Engineers should have:
- •An understanding of industrial safety standards and regulations.
- •Ability to interpret electrical and mechanical schematics.
- •Skills in data analysis for system performance evaluation and optimization.
- •Adaptability to learn new technologies and processes.
- •A proactive approach to continuous improvement and innovation.
The field of automation is rapidly growing, providing ample career advancement opportunities. Automation Controls Engineers can progress to roles such as Senior Engineer, Project Manager, or Technical Director.
Continuous education and certifications can further enhance career prospects.
Salaries for Automation Controls Engineers can vary based on experience, location, and industry. On average, their salaries range from $70,000 to $110,000 annually, with potential for bonuses and advancements in high-demand areas.
Frequently Asked Questions
Ready to Apply?
Use our AI-powered tools to create a perfect resume and cover letter tailored to this role.
Key Responsibilities
1.
- •Write, modify, and test PLC logic (Allen-Bradley, Siemens) and SCADA screens to control up to 50 production lines. This keeps machines running to meet daily throughput targets (e.g., 20,000 units/day).
- •Why it matters: correct code prevents stoppages and ensures setpoint control; how it contributes: improves on-line availability toward a 98% uptime goal.
2.
- •Diagnose electrical and control faults using multimeter, oscilloscope, and software trace tools; respond to critical alarms within 30 minutes during shift rotations.
- •Why: minimizes mean time to repair (MTTR); impact: reduces unplanned downtime by 15–30%.
3.
- •Lead on-site commissioning for new machines: execute factory acceptance tests (FAT), site acceptance tests (SAT), and punch-list resolution; achieve >95% first-pass acceptance where possible.
- •Why: validates design and reduces post-startup rework; contributes to on-time project delivery.
4.
- •Create control schematics, BOMs, and panel layouts (UL508A), including wire lists and component selection.
- •Why: ensures safe, code-compliant installations; contributes to lower build cost and easier field maintenance.
5.
- •Tune PID loops, implement sequence improvements, and collect performance data to reduce cycle time by 5–20%.
- •Why: increases yield and efficiency; contributes to cost-per-unit reduction.
6.
- •Produce version-controlled PLC code, wiring diagrams, and operator SOPs; train operators and maintenance staff each release.
- •Why: speeds troubleshooting and knowledge transfer; contributes to consistent operations.
7.
- •Implement safety interlocks, perform risk assessments per IEC 62061/ISO 13849, and apply basic IEC 62443 cybersecurity patches.
- •Why: protects people and IP; contributes to regulatory compliance and reduced liability.
Actionable takeaway: Prioritize daily uptime tasks, schedule weekly tuning and documentation updates, and include safety/cyber checks in every project plan.
Required Qualifications
Technical skills
- •PLC programming (must): 3+ years with RSLogix/Studio 5000 or Siemens TIA Portal; used daily to build ladder/FBD/structured text logic.
- •SCADA/HMI (must): experience with Wonderware, Ignition or FactoryTalk to design operator screens and alarms that reduce operator errors by 25%.
- •Industrial networks (must): Ethernet/IP, PROFINET, Modbus TCP; used to integrate PLCs, drives and MES.
- •Instrumentation & motion (must): configure VFDs, PID loops, RTDs, thermocouples and torque sensors for precise control.
- •Scripting/IT (nice-to-have): Python or SQL for data logging, alarms analytics, and basic Git version control.
Soft skills
- •Troubleshooting: methodical fault isolation under time pressure; shown by resolving 80% of control faults without vendor support.
- •Communication: write clear SOPs and lead cross-functional meetings with production and quality teams.
- •Project management: manage scope/timeline for 3–5 control projects per year.
Education & certifications
- •Degree: Bachelor’s in Electrical, Controls, Mechatronics, or equivalent hands-on experience (minimum Associate + 5 years).
- •Certifications (preferred): ISA Certified Automation Professional (CAP), PLC vendor certifications, OSHA 10/30, UL508A training.
- •Safety/cyber (must/important): familiarity with NFPA70E, IEC 61508 or IEC 62443 for safety/cyber practices.
Experience requirements
- •Must-have: 3–5 years in industrial controls with commissioning experience on at least 3 machine installations; proven record of improving uptime or reducing cycle time by measurable amounts (e.g., 10–20%).
- •Nice-to-have: robotics integration, machine vision, MES/ERP interfacing, or IIoT deployments that capture production KPIs.
Actionable takeaway: hire for strong PLC/SCADA competence plus hands-on commissioning experience; prioritize candidates with demonstrated uptime or efficiency improvements.