Senior Controls Engineer - TPM

We are seeking a highly skilled and experienced Senior Controls Engineer with a strong background in industrial automation and a deep expertise in CoDeSys for PLC programming. The successful candidate will play a critical role in the design, development, implementation, and commissioning of complex control systems for our [products/systems/manufacturing processes]. This role requires a hands-on approach, strong problem-solving skills, and the ability to lead technical initiatives while mentoring junior engineers, all with a keen understanding of manufacturing principles and operational efficiency.

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Key Responsibilities

System Design & Architecture

•  Lead the conceptualization, design, and specification of complex control systems, including hardware selection (PLCs, HMIs, drives, sensors, actuators) and network architecture.
•  Develop detailed electrical schematics, I/O lists, and wiring diagrams in collaboration with electrical engineers.
•  Define control strategies, safety interlocks, and operational sequences, always considering manufacturing process flow, cycle time optimization, and overall equipment effectiveness (OEE).

CoDeSys Programming & Development (Core Responsibility)

• Expertly program, test, and debug PLC logic using CoDeSys (IEC 61131-3) in various languages (ST, FBD, LD, SFC).
• Develop and implement reusable CoDeSys libraries, function blocks, and structured text routines, ensuring solutions are robust, maintainable, and scalable for production environments.
• Integrate and configure various fieldbus protocols (e.g., EtherCAT, PROFINET, Modbus TCP/IP, CANopen) within the CoDeSys environment.
• Develop and integrate HMI/SCADA applications using CoDeSys visualization or other compatible platforms, prioritizing operator usability, process visibility, and diagnostic capabilities for manufacturing personnel.

Commissioning & Troubleshooting

• Lead the on-site commissioning, testing, and tuning of control systems, ensuring optimal performance and adherence to specifications, with a focus on achieving production targets and minimizing downtime.
• Perform advanced troubleshooting and diagnostics of complex hardware and software issues, often under pressure in a live manufacturing environment.
• Collaborate with mechanical, electrical, and software engineers to resolve system integration challenges, understanding their impact on the manufacturing line

•Documentation & Standards

• Create and maintain comprehensive technical documentation, including functional specifications, design documents, test plans, and as-built drawings, which are essential for long-term manufacturing support and maintenance.
• Ensure all control system designs and implementations comply with relevant industry standards (e.g., UL, CE, NFPA, ISO, ANSI) and manufacturing specific regulations.
• Adhere to established coding standards and best practices for CoDeSys development.

Project Leadership & Mentorship

• Lead technical aspects of projects, including scope definition, scheduling, and resource allocation, considering production timelines and resource availability within a manufacturing context.
• Provide technical guidance and mentorship to junior controls engineers, fostering their development in CoDeSys and control system design with an emphasis on practical manufacturing applications.
• Participate in design reviews and provide constructive feedback.

Continuous Improvement & Manufacturing Optimization

• Stay abreast of new technologies, industry trends, and best practices in industrial automation and CoDeSys, specifically those applicable to improving manufacturing processes and efficiency.
• Proactively identify opportunities for process improvement, standardization, cost reduction

 

• Education: Bachelor's degree in Electrical Engineering, Mechatronics Engineering, Computer Engineering, or a closely related engineering discipline from an accredited university. Master's degree a plus.
• Experience: Minimum of 7+ years of progressive experience in industrial control systems design, programming, and commissioning, with a significant portion in manufacturing or production environments.
• Minimum of 3+ years of dedicated, hands-on experience programming and developing complex applications with CoDeSys (all versions/compatible platforms are valuable) for industrial machinery or production lines.
• Proven experience leading technical aspects of control system projects, from concept to production readiness.\
• Technical Skills (Must-Haves): Expert-level proficiency in CoDeSys (IEC 61131-3) programming.
• Strong understanding of industrial networking protocols (e.g., EtherCAT, PROFINET, Modbus TCP/IP, CANopen, Ethernet/IP).
• Proficient with HMI/SCADA development and integration, with an emphasis on intuitive operator interfaces and robust data acquisition for manufacturing analytics.
• Solid understanding of electrical control panel design principles and safety standards (e.g., NFPA 79, UL 508A, EN ISO 13489, IEC 60204), and their application in a manufacturing plant.
• Experience with industrial safety systems (e.g., safety PLCs, light curtains, emergency stops) as applied to production equipment and personnel safety.
• Familiarity with CAD software for electrical design (e.g., AutoCAD Electrical, EPLAN).
• Ability to read and interpret complex electrical schematics and mechanical drawings.
• Demonstrated understanding of manufacturing processes, including but not limited to: material handling, assembly, machining, packaging, process control, and quality inspection.
• Knowledge of key manufacturing metrics such as OEE, cycle time, throughput, and their impact on control system design.
• Soft Skills: Excellent analytical and problem-solving abilities, particularly in diagnosing and resolving production issues.
• Strong written and verbal communication skills, able to convey complex technical information to production, maintenance, and management teams.
• Ability to work independently and as part of a multidisciplinary team, including collaboration with production operators and maintenance technicians.
• Demonstrated leadership potential and ability to mentor.
• Strong attention to detail and commitment to quality.
• Ability to manage multiple priorities and meet deadlines in a fast-paced manufacturing environment.
• Competitive Salary
• Competitive Time Away from Work Policy
• Paid Time Off (PTO): 16 days (Up to 30 days based on seniority)
• Personal Days (PAA): 5 days
• Company Paid Holidays: 9 days
• Paid Parental Leave: 6 Weeks
• Industry Best Retirement Benefit
• 401k - 75% match up to the first 9% contribution
• Unique Bosch Defined Contribution (BDC) plan provides 100% company-funded 401(k) contributions , ranging from 2.5% to 6.5% of your pay, helping you secure your financial future
• Student Debt Retirement Savings Match
• Profit Sharing Bonus (CPrP) up to 10%
• Medical, dental, and vision coverage
• Onsite Cafeteria with multiple menu options
• Onsite Starbucks Cafe
• Onsite Bosch Store (Employee Discount)

Your well-being matters at Bosch! We offer a competitive compensation and a benefits package designed to empower you in every area of your life. This includes premium health coverage, a 401(k) with generous matching, resources for financial planning and goal setting, ample paid time off, parental leave, and comprehensive life and disability protection. We're investing in your success!  Bosch Benefits | Bosch in the USA

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• Indefinite U.S. work authorized individuals only. Future sponsorship for work authorization is not available.
• Equal Opportunity Employer, including disability / veterans.