Senior Controls Engineer

As a Senior Controls Engineer at TSM, you will be a key architect in shaping the future of intelligent manufacturing across our engineered-products division. This role bridges operational technology (OT) and information technology (IT), overseeing the development and integration of scalable, high-performance automation systems—from PLC/HMI-level control through Manufacturing Execution Systems (MES) and Digital Twin simulations. 

You will drive initiatives that improve manufacturing agility, product traceability, and decision-making accuracy by enabling smart factory capabilities and real-time process visibility. This is a hands-on, strategic role where you will collaborate with cross-functional teams to deliver systems that not only control machinery but also unlock predictive insights and continuous improvement opportunities. Your work will directly impact throughput, quality, and digital transformation readiness across multiple sites and product lines.

Locations: Huntersville/Hickory/High Point, NC

Schedule: Hybrid flexibility

HSM Transportation is an ISO Certified exclusive complete line manufacturer of C.E. White School Bus Seats, portable child restraints, seat covers, and foam aftermarket parts. We are also a premier commercial seat manufacturer specializing in luxury full-size, luxury shuttle, commuter transit, commuter van, salon, foldaway and sofa seating.

HSM Transportation Solutions is a business unit of HSM, headquartered in Hickory, NC since 1944. Our commitment to excellence goes far beyond our products and processes; it is centered on the people who make it all possible. If you're interested in learning more about our company culture, as well as the benefits we offer our employees, please visit our website or social media pages.

Controls Architecture & Development

• Design and implement PLC logic (Allen-Bradley, Siemens, or equivalent) for automated assembly, testing, and material handling systems.
• Develop and configure HMIs/SCADA interfaces to provide operators with intuitive dashboards, alarm management, and trending.
• Ensure system resilience and safety by applying fail-safe logic, redundancy planning, and safety interlocks in compliance with regulatory standards.
• Support system validation through structured simulation, testing, and troubleshooting during installation and commissioning phases.

MES Integration & Tech-Stack Management

• Lead the end-to-end integration of Manufacturing Execution Systems (Ignition MES, FactoryTalk, Wonderware, or similar) with plant floor controls and enterprise systems (ERP, QMS).
• Define data models, OPC UA/MQTT communications, and unified namespace architecture to ensure reliable data flow and traceability.
• Collaborate with IT and cybersecurity teams to implement secure, scalable infrastructure for MES and industrial data exchange.
• Manage lifecycle updates for MES platforms, ensuring minimal disruption to operations during version upgrades or configuration changes.

Digital Twin & Simulation

• Create and maintain digital twin models (using TwinCAT, Siemens Digital Industries Software, Dassault 3DEXPERIENCE or equivalent) to simulate production lines, validate control strategies, and optimize throughput.
• Collaborate with process engineers and data scientists to incorporate real-time sensor inputs, KPIs, and “what-if” scenario analyses.
• Utilize simulation tools to test new product introductions (NPI) and plant layout changes before physical implementation.
• Analyze performance gaps using model-based diagnostics to proactively identify areas for optimization and cost savings.
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Project Leadership & Cross-Functional Collaboration

• Serve as the technical lead on automation projects, from scoping and requirements through FAT, SAT, and commissioning.
• Partner with manufacturing, quality, IT, and data teams to align control solutions with business objectives, compliance standards, and cybersecurity best practices.
• Coordinate vendor management and oversee contractor contributions to ensure adherence to project scope, schedule, and technical standards.
• Provide technical leadership during strategic capital investment initiatives tied to automation, MES expansion, or facility upgrades.
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Continuous Improvement & Support

• Drive continuous improvement by analyzing downtime, performing root-cause investigations, and deploying software updates or control tweaks.
• Mentor junior engineers, develop standards and best practices, and maintain comprehensive documentation (P&IDs, E-codes, functional specs).
• Support plant maintenance and operations teams by troubleshooting control issues and implementing robust corrective actions.
• Regularly audit control system performance and recommend digital enhancements to sustain high OEE and productivity targets.
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Education & Experience

• Bachelor’s degree in Electrical, Controls, or Mechatronics Engineering (Master’s a plus).
• 7+ years of hands-on experience in industrial controls engineering within a discrete or hybrid manufacturing environment.
• Proven track record of leading automation and MES projects from concept through deployment.
• Experience working in multi-site or highly engineered product environments is preferred.

Technical Skills

• PLC & HMI/SCADA: Proficient with Allen-Bradley ControlLogix, Siemens S7/TIA Portal, or equivalent platforms; strong experience with HMI/SCADA systems such as FactoryTalk View, WinCC, and Ignition.
• MES & Data Integration: Deep experience configuring Ignition MES, Wonderware MES, or FactoryTalk ProductionCentre; strong working knowledge of OPC UA, MQTT, SQL, and REST/SOAP API integrations.
• Digital Twin Modeling: Hands-on experience building and validating digital twins using TwinCAT 3, Siemens Simatic IT DT, Dassault 3DEXPERIENCE, or Ansys platforms.
• Programming & Scripting: Skilled in ladder logic, structured text, function block programming, and scripting languages such as Python or JavaScript for automation and data handling.
• Industrial Networking & Cybersecurity: Familiarity with Ethernet/IP, PROFINET, and Modbus TCP; understanding of VLANs, firewall segmentation, and ISA/IEC 62443 cybersecurity practices.

Soft Skills

• Strong analytical and problem-solving skills with a data-driven mindset.
• Excellent communicator, capable of translating complex technical systems to non-technical stakeholders.
• Highly collaborative, with the ability to work cross-functionally in fast-paced, evolving environments.
• Self-starter with the ability to manage multiple high-impact initiatives simultaneously.
• Committed to mentoring others and promoting technical excellence and standardization across teams.

Travel

• Travel within North Carolina and to other states is required.
• Estimated travel time: approximately 20%.

As a Senior Controls Engineer at HSM, you’ll enjoy: 

• 401k Contribution Match up to 4% (100% Vested from Day 1), 9 paid holidays, 3 weeks of vacation (Eligible after 60 days), Affordable Total Package Benefits offerings for you and your family, On-Site No-Cost Medical Clinics for you and Covered Dependents, Teladoc 24/7 ($0 copay), Global Healthcare and Tuition Reimbursement & Professional Development Assistance.  

At HSM Solutions our culture is built on a foundation of teamwork, innovation, and celebrating our successes together as a team. We provide our employees with the tools and resources they need to achieve their goals and to make a meaningful impact on our customers, our company, and our communities. If you're looking for a place that's not just a job, but a spot where you can grow and make a real impact, then HSM Solutions is the place for you. 

If you would like to apply for a position, please visit our career site at www.hsmsolutions.com/careers for a prompt response from our recruitment team. If you have any questions or would like to follow up on your application, please don't hesitate to contact us at jobs@hsmsolutions.com.

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HSM prohibits discrimination based on any protected status, workplace harassment/bullying, and retaliation for filing a complaint or providing information related to a complaint. HSM provides equal employment opportunity to all employees and applicants without regard to an individual's protected status: race/ethnicity, color, national origin, ancestry, sex/gender, gender identity/expression, sexual orientation, marital/parental status, pregnancy/childbirth or related conditions, religion, creed, age, disability, genetic information, veteran status, or any other protected status.