Lead Controls Engineer in Arlington
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Job DescriptionJob Description
Title: Lead Controls Engineer
Location: Arlington, TX
Hire Type: Direct Hire
Compensation: $160,000 to $190,000 based on experience
Leading provider of advanced manufacturing solutions within the defense and energetics sectors is seeking a Lead Automation Controls Engineer to help drive the design, engineering, and integration of turnkey production lines for energetics materials and munitions. These systems support government agencies, military contractors, and defense OEMs worldwide.
This role is designed for a senior-level technical leader who is interested in growing into a Controls Engineering Manager position as the organization continues to expand. The Lead Controls Engineer will provide hands-on technical leadership while helping establish standards, mentor engineers, and guide automation strategy across multiple projects.
You will work closely with project managers, mechanical engineers, software developers, clients, and key stakeholders to deliver high-performance, compliant automation systems from concept through commissioning. In addition to technical execution, this role will influence best practices, coordinate engineering efforts, and support the development of a high-performing controls team.
You will also lead onsite commissioning efforts, troubleshoot complex automation systems, and perform final validation to ensure solutions meet strict safety, regulatory, and production requirements. Experience with SCADA platforms is highly .
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Responsibilities:
Technical Leadership & Engineering:
· Serve as the technical lead for controls engineering projects, guiding architecture, programming standards, and system design.
· Develop, program, test, and troubleshoot Allen-Bradley PLCs (ControlLogix, CompactLogix, MicroLogix).
· Create and modify programs using ladder logic, structured text, and function block programming.
· Lead system commissioning and automation upgrades for complex manufacturing systems.
· Program, configure, and optimize industrial robots (Fanuc, ABB, KUKA, or similar).
· Integrate robotics, third-party systems, and vision solutions with PLC and SCADA platforms.
· Support robotic applications including assembly, material handling, packaging, and custom automation.
· Perform robot teaching, path optimization, and cycle-time improvements.
System Design & Integration:
· Coordinate with vendors, integrators, and subcontractors for panel fabrication, robotics integration, and SCADA development.
· Apply applicable standards such as UL 508A, NFPA 79, ISO 13849, and DoD cybersecurity requirements.
· Size and specify motors, drives, sensors, safety components, and automation hardware.
· Design electrical control panels, including schematics, layouts, and component selection.
· Generate documentation including wiring diagrams, bills of materials, and panel build instructions.
· Oversee internal and external panel build technicians during fabrication.
· Integrate PLCs, robots, HMIs, sensors, drives, and related equipment.
· Implement industrial networks and communication protocols (EtherNet/IP, DeviceNet, PROFINET, EtherCAT).
Team Leadership & Future Management:
· Provide technical mentorship to junior and mid-level controls engineers.
· Help establish controls engineering standards, documentation practices, and programming templates.
· Support project managers with technical planning, scheduling, and risk mitigation.
· Participate in hiring, onboarding, and development of controls engineering staff.
· Contribute to department growth and future team structure, with the opportunity to transition into a Controls Engineering Manager role as the team expands.
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Qualifications:
· 10+ years of industrial automation experience, including at least 5 years supporting complex custom automation projects.
· Strong expertise in Allen-Bradley PLC programming (Studio 5000).
· Experience with robot programming (Fanuc, ABB, KUKA, or similar).
· Proficiency with AutoCAD Electrical.
· Experience developing HMI interfaces (PanelView or similar).
· Strong understanding of control panel design, electrical systems, and industrial wiring standards.
· Familiarity with machine safety standards (ISO 13849, ANSI/RIA, NFPA 79).
· Experience with automation components including VFDs, motion control systems, safety systems, sensors, and industrial networks.
· Proven ability to troubleshoot complex automation challenges in production environments.
· Bachelor’s degree in Electrical Engineering, Mechatronics, Automation, or related field.
Experience
· Experience developing or implementing SCADA systems (Ignition, AVEVA Edge/InduSoft, FactoryTalk View, Wonderware).
· Experience with machine vision or advanced inspection systems.
· Exposure to machine learning–based inspection systems.
· Experience supporting DoD or government-funded automation programs.
· Demonstrated technical leadership and project ownership.
· Strong analytical, communication, and documentation skills.
· Ability to manage multiple projects and shifting priorities.
· Willingness to travel (~10% during design; up to 50%+ during commissioning).
· Self-motivated with a continuous improvement mindset.
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Compensation & Benefits
· Competitive base salary aligned with experience.
· Performance-based incentive opportunities.
· Generous employer contribution toward medical insurance (75%+ of employee premium).
· Dental, vision, and gap coverage options.
· Employer-paid life insurance and short-term .
· 401(k) with employer match and immediate vesting.
· Generous paid time off policy.
Qualified applicants will receive consideration for employment without regard to , , , , , , , , , protected veteran status, or genetic information.
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