1. Role Overview

The Senior Controls Engineer is responsible for the design, development, testing,

commissioning, deployment and lifecycle support of PLC-based industrial automation

systems. The role encompasses PLC software development, control system architecture,

motion control, industrial networking, HMI/SCADA integration, electrical controls, system

commissioning, troubleshooting and customer support for crane automation, transfer car

automation, material handling systems and other industrial automation projects.

2. Key Responsibilities

PLC Software Development

• Develop PLC software using IEC 61131-3 languages (ST, LD, FBD and SFC where applicable).

• Develop modular software using FBs, FCs, DBs, UDTs and reusable libraries.

• Configure PLC hardware, remote I/O and distributed control architectures.

• Develop and optimize machine sequences, positioning and motion control applications.

• Perform software simulation, testing and debugging.

System Integration

• Integrate PLCs with HMI/SCADA, drives, sensors, remote I/O and third-party equipment.

• Configure and troubleshoot PROFINET, PROFIBUS, Ethernet/IP, Modbus TCP/IP and OPC UA.

• Configure Industrial LAN/WLAN infrastructure.

Commissioning & Site Activities

• Lead FAT, SAT and on-site commissioning.

• Tune positioning, drive and motion parameters.

• Troubleshoot PLC, communication, electrical and field device issues.

• Support customer acceptance and system handover.

Electrical Controls

• Interpret electrical schematics and control drawings.

• Support VFDs, MCCs, switchgear and field wiring verification.

• Validate machine safety interlocks and electrical commissioning.

Documentation & Leadership

• Prepare FDS, SDS,



I/O lists, commissioning reports and software backups.

• Maintain software version control and technical documentation.

• Mentor junior engineers and coordinate with customers, contractors and project teams.

3. Required Technical Skills

PLC Platforms: Siemens TIA Portal, STEP7, S7-1200, S7-1500

Programming: Structured Text (ST), Ladder Diagram (LD), Function Block Diagram (FBD),Sequential Function Chart (SFC)

Motion Control: Absolute/Relative Positioning, Encoder Feedback, VFD Applications

Industrial Communication: PROFINET, PROFIBUS, Ethernet/IP, Modbus TCP/IP, OPC UA

Automation: Crane Automation, Transfer Cars, Material Handling Systems, Safety PLCs

Electrical: Control Panels, MCCs, Motor Control, Instrumentation, Electrical Commissioning

HMI/SCADA: WinCC and similar HMI/SCADA platforms

4. Qualifications

• Bachelor's Degree in Electrical, Electrical & Electronics, Instrumentation or Automation

Engineering.

• Industrial Automation certification is an advantage.

5. Experience

• 812 years of industrial automation experience.

• Minimum 7 years of hands-on PLC programming.

• Experience in software development, commissioning and troubleshooting of PLC-based

automation systems.

• Experience in crane automation, transfer cars or material handling systems is highly desirable.

• Experience leading multidisciplinary engineering and commissioning teams.

6. Preferred Skills

• Functional Safety (SIL/PL) and Safety PLC programming.

• PLC migration projects and reusable software architecture.

• Version control and software lifecycle management.

• Industrial Cybersecurity awareness.

• Solid analytical, communication and customer-facing skills.

📌 Sr. Controls Engineer (Mumbai)
🏢 EMeasurematics
📍 Mumbai