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What does a senior controls engineer do?

Updated January 8, 2025
8 min read
What does a senior controls engineer do

A senior controls engineer specializes in designing and developing control systems in various industries. Their responsibilities typically include identifying and understanding the company's needs, producing prototypes and test structures, gathering and analyzing data to identify areas needing improvement, implementing solutions in vulnerable areas, and providing technical support when necessary. Furthermore, as a senior controls engineer, it is essential to lead and serve as a mentor to junior engineers, all while enforcing the company's policies and regulations.

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Senior controls engineer responsibilities

Here are examples of responsibilities from real senior controls engineer resumes:

  • Manage all G/L, A/R, A/P, bank, loans and equity accounts.
  • Design reporting system using MatLab program to automate daily and weekly report.
  • Lead the management team in implementing MISys which fully intergrade QuickBooks regarding the manufacturing process.
  • Manage all aspects of business start-up, advance daily accounting, and month- and year-end functions.
  • Establish communication links and prepare machines for bench-testing to attain UL certification.
  • Develop motion control code to communicate with an Allen-Bradley PLC through TCP/IP.
  • Coordinate activities with CPA to file year-end tax returns and annual certify audit.
  • Assign to provide tagging system at SPI hard/soft tags base on PID's.
  • Maintain required safety training and compliance; specifically from IEC, API, ASTM and NACE.
  • Handle installation, programming, and repairs of PLC, SCADA, and HMI systems including automate overhead cranes.
  • Design large scale HMI and SCADA packages for various systems including those mention above as well as pipeline systems.
  • Experience with daily operations, preparation of consolidate financial statements, tax planning/preparation, payroll, sales tax, and QuickBooks.
  • Debug and start-up at site.
  • Implement QuickBooks features previously not used.
  • Assist with end of month reverse logistics.

Senior controls engineer skills and personality traits

We calculated that 11% of Senior Controls Engineers are proficient in Control Systems, HMI, and C++. They’re also known for soft skills such as Concentration, Initiative, and Math skills.

We break down the percentage of Senior Controls Engineers that have these skills listed on their resume here:

  • Control Systems, 11%

    Design and implementation of electrical control systems for complex automated manufacturing equipment using Allen-Bradley CompactLogix and ContolLogix processors and FactoryTalk View.

  • HMI, 9%

    Developed Master PLC (MicroLogix 1400) and HMI (Schneider Electric) programs to be used on all future projects.

  • C++, 7%

    Design and implementation of interfacing for multiple controls platforms using OPC and High level software such as VB, and C++.

  • Allen-Bradley, 6%

    Program Allen-Bradley PanelView, PanelView+, and PanelView +6 touch screens.

  • SCADA, 5%

    Programmed and installed supervisory SCADA systems for major water treatment facilities.

  • MATLAB, 4%

    Designed reporting system using MatLab program to automate daily and weekly report.

Common skills that a senior controls engineer uses to do their job include "control systems," "hmi," and "c++." You can find details on the most important senior controls engineer responsibilities below.

Concentration. To carry out their duties, the most important skill for a senior controls engineer to have is concentration. Their role and responsibilities require that "electrical and electronics engineers design and develop complex electrical systems and electronic components and products." Senior controls engineers often use concentration in their day-to-day job, as shown by this real resume: "design, programming and installation of process control equipment for variety of customers with special concentration in the plastic compounding industry. "

Initiative. Another soft skill that's essential for fulfilling senior controls engineer duties is initiative. The role rewards competence in this skill because "electrical and electronics engineers must apply their knowledge to new tasks in every project they undertake." According to a senior controls engineer resume, here's how senior controls engineers can utilize initiative in their job responsibilities: "led the controls team in execution of capital projects and tactical initiatives in the world's fifth largest food company. "

Math skills. senior controls engineers are also known for math skills, which are critical to their duties. You can see how this skill relates to senior controls engineer responsibilities, because "electrical and electronics engineers must use the principles of calculus and other advanced math in order to analyze, design, and troubleshoot equipment." A senior controls engineer resume example shows how math skills is used in the workplace: "perform mathematical system analysis at both the micro/macro levels, utilizing technical computing tools - matlab and simulink. "

Speaking skills. senior controls engineer responsibilities often require "speaking skills." The duties that rely on this skill are shown by the fact that "electrical and electronics engineers work closely with other engineers and technicians." This resume example shows what senior controls engineers do with speaking skills on a typical day: "ensured that data was correctly represented to the operating authority in hmi's at the central plant control room. "

Writing skills. Another crucial skill for a senior controls engineer to carry out their responsibilities is "writing skills." A big part of what senior controls engineers relies on this skill, since "electrical and electronics engineers develop technical publications related to equipment they develop, including maintenance manuals, operation manuals, parts lists, product proposals, and design methods documents." How this skill relates to senior controls engineer duties can be seen in an example from a senior controls engineer resume snippet: "start to finish electrical designing and writing of plc software for siemens s7 platform and allen bradley. "

Most common senior controls engineer skills

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Compare different senior controls engineers

Senior controls engineer vs. Engineering trainee

An engineering trainee is responsible for shadowing engineers in their duties and performing administrative tasks as needed. Engineering trainees assist the engineers in inspecting construction sites and conducting field research. They also identify cost-efficient materials and resources that meet quality standards and client specifications. An engineering trainee must have excellent communication and organizational skills, especially in writing reports, attending meetings, and ensuring that all reports are submitted for management's reviews, such as contracts from suppliers and vendors.

If we compare the average senior controls engineer annual salary with that of an engineering trainee, we find that engineering trainees typically earn a $47,063 lower salary than senior controls engineers make annually.While their salaries may differ, the common ground between senior controls engineers and engineering trainees are a few of the skills required in each roleacirc;euro;trade;s responsibilities. In both careers, employee duties involve skills like control systems, c++, and matlab.

These skill sets are where the common ground ends though. The responsibilities of a senior controls engineer are more likely to require skills like "hmi," "allen-bradley," "scada," and "project management." On the other hand, a job as an engineering trainee requires skills like "excellent interpersonal," "fire protection," "r," and "boilers." As you can see, what employees do in each career varies considerably.

Engineering trainees earn the highest salaries when working in the energy industry, with an average yearly salary of $63,253. On the other hand, senior controls engineers are paid more in the automotive industry with an average salary of $109,075.The education levels that engineering trainees earn slightly differ from senior controls engineers. In particular, engineering trainees are 0.3% more likely to graduate with a Master's Degree than a senior controls engineer. Additionally, they're 0.6% less likely to earn a Doctoral Degree.

Senior controls engineer vs. Radio frequency engineer

A radio frequency engineer, also known as RF engineer, specializes in designing and developing communication systems using radio waves. One of their primary responsibilities revolves around creating networks and systems and testing equipment. They make sure that equipment is up to high standards by traveling to different areas as needed, troubleshooting issues to identify the root of problems and performing corrective measures required. Furthermore, a radio frequency engineer must continuously optimize equipment quality and ensure efficiency while adhering to the laws and regulations.

Radio frequency engineer positions earn lower pay than senior controls engineer roles. They earn a $18,997 lower salary than senior controls engineers per year.While the salary may differ for these jobs, they share a few skills needed to perform their duties. Based on resume data, both senior controls engineers and radio frequency engineers have skills such as "system design," "technical support," and "java. "

While some skills are similar in these professions, other skills aren't so similar. For example, resumes show us that senior controls engineer responsibilities requires skills like "control systems," "hmi," "c++," and "allen-bradley." But a radio frequency engineer might use other skills in their typical duties, such as, "test equipment," "antenna," "system performance," and "troubleshoot."

On average, radio frequency engineers earn a lower salary than senior controls engineers. Some industries support higher salaries in each profession. Interestingly enough, radio frequency engineers earn the most pay in the technology industry with an average salary of $94,522. Whereas senior controls engineers have higher pay in the automotive industry, with an average salary of $109,075.radio frequency engineers earn similar levels of education than senior controls engineers in general. They're 4.5% more likely to graduate with a Master's Degree and 0.6% more likely to earn a Doctoral Degree.

Senior controls engineer vs. Circuit design engineer

A circuit design engineer specializes in designing and developing electrical components and circuits in devices and machinery. Among their responsibilities include identifying the needs of every project, developing strategies to attain optimal quality, developing diagrams and test structures, troubleshooting, and repairing issues. They must also perform regular maintenance checks on existing systems and perform upgrades and corrective measures as needed. Moreover, a circuit design engineer typically works in a team setting, which requires an active communication line for a smooth and efficient workflow.

An average circuit design engineer eans a higher salary compared to the average salary of senior controls engineers. The difference in salaries amounts to circuit design engineers earning a $396 higher average salary than senior controls engineers.By looking over several senior controls engineers and circuit design engineers resumes, we found that both roles require similar skills in their day-to-day duties, such as "matlab," "ethernet," and "i/o." But beyond that, the careers look very different.

The required skills of the two careers differ considerably. For example, senior controls engineers are more likely to have skills like "control systems," "hmi," "c++," and "allen-bradley." But a circuit design engineer is more likely to have skills like "circuit design," "cmos," "rf," and "verilog."

Circuit design engineers earn the best pay in the technology industry, where they command an average salary of $114,509. Senior controls engineers earn the highest pay from the automotive industry, with an average salary of $109,075.circuit design engineers typically earn similar educational levels compared to senior controls engineers. Specifically, they're 1.0% more likely to graduate with a Master's Degree, and 1.0% more likely to earn a Doctoral Degree.

Senior controls engineer vs. Engineer

Engineers are highly trained professionals who determine the feasibility of various projects, usually related to the construction industry. They are considered experts in mathematics and science, two disciplines that they need to use in designing and coming up with plans for projects. They should also be well-versed in different construction or industrial materials, and they ensure that appropriate materials are used for the project. They also ensure that the projects meet the requirements of the groups that hired them. They create spaces that would both address the needs of the end-users and the industry standards. They also ensure that the projects they make would stand the test of time.

Engineers average a lower salary than the annual salary of senior controls engineers. The difference is about $15,221 per year.According to resumes from senior controls engineers and engineers, some of the skills necessary to complete the responsibilities of each role are similar. These skills include "control systems," "c++," and "matlab. "

Even though a few skill sets overlap between senior controls engineers and engineers, there are some differences that are important to note. For one, a senior controls engineer might have more use for skills like "hmi," "allen-bradley," "scada," and "ul." Meanwhile, some responsibilities of engineers require skills like "python," "cloud," "c #," and "aws. "

In general, engineers earn the most working in the automotive industry, with an average salary of $97,672. The highest-paying industry for a senior controls engineer is the automotive industry.In general, engineers hold similar degree levels compared to senior controls engineers. Engineers are 2.6% less likely to earn their Master's Degree and 0.0% more likely to graduate with a Doctoral Degree.

Types of senior controls engineer

Updated January 8, 2025

Zippia Research Team
Zippia Team

Editorial Staff

The Zippia Research Team has spent countless hours reviewing resumes, job postings, and government data to determine what goes into getting a job in each phase of life. Professional writers and data scientists comprise the Zippia Research Team.

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