Senior Controls Engineer

About the role

The is responsible for architecting and deploying advanced control strategies that directly enhance the safety and efficiency of medical waste handling operations. This role demands a high level of ownership over the entire system lifecycle, from initial concept and simulation through to final commissioning and continuous improvement. You will be the primary technical lead for designing, programming, and troubleshooting complex automated systems that integrate programmable logic controllers, robotic manipulators, and sophisticated machine vision technologies. The successful candidate will thrive on solving intricate sequential logic problems where precision, reliability, and adherence to strict safety protocols are non-negotiable requirements. You will translate abstract operational goals into concrete technical specifications, ensuring that every automated solution supports the core mission of protecting people and the planet. This position offers the opportunity to work on high-scale manufacturing processes that have a direct and positive impact on public health and environmental safety. You will be instrumental in defining the technical standards and best practices that govern automation within the company's global healthcare waste management infrastructure.

Key facts

What you'll do

• Architect and implement control logic for automated medical waste processing systems, ensuring seamless integration between PLCs, robotics, and vision sensors.
• Design and optimize intake workflows that capture real-time sensor data and map this information to control sequences for the categorization and segregation of medical waste.
• Configure and execute build sequences where PLC code governs actuators and safety devices to guarantee reliable, consistent, and safe operation in high-throughput environments.
• Define, manage, and oversee review checkpoints for validating vision algorithms and robotic motion paths prior to system release and deployment.
• Coordinate shipping activities and operational testing, aligning test results with facility throughput targets and strict regulatory compliance mandates.
• Establish and maintain partner synchronization by defining the software and hardware interfaces that connect equipment control systems with broader facility management platforms.
• Model the behavior of robotic arms and end-effectors to ensure pick routines are robust enough to accommodate varied container shapes and sizes without constant manual intervention.
• Implement and refine vision checks for label inspection, barcode reading, and container condition assessment to function reliably in harsh, demanding production environments.
• Perform root cause analysis on system malfunctions or process deviations, developing and deploying corrective actions that uphold safety and quality standards.
• Maintain comprehensive documentation trails, including parameter changes, logic updates, and configuration revisions, to support internal audits and regulatory compliance.
• Collaborate closely with cross-functional teams to ensure that automation solutions are scalable, maintainable, and aligned with evolving business objectives.
• Drive continuous improvement initiatives by analyzing system performance data, identifying bottlenecks, and proposing enhancements to increase efficiency and reliability.
• Mentor junior engineers and technicians on control system design, troubleshooting methodologies, and safety best practices within the automation framework.
• Ensure all engineering deliverables adhere to industry standards and regulatory requirements specific to medical waste handling and processing.
• Act as the technical authority for automation equipment, providing expert guidance during installation, commissioning, and ongoing support.

Requirements

• Must possess three to five years of controls engineering experience, with a demonstrated history of working in medical, regulated, or highly controlled environments.
• A strong understanding of PLC ladder logic and function block methodologies is mandatory for developing high-speed manufacturing tasks and safety-critical applications.
• Proficiency with industrial vision systems and their integration into triggers for sorting, verification, and inspection is a strict requirement for this role.
• The ability to travel across the United States and Canada is necessary, including mandatory travel to Taylor, Michigan, for induction training and project activities.
• Individuals must demonstrate the capability to manage complex automation issues from initial design through to stable production deployment and beyond.
• A commitment to maintaining the highest standards of safety, quality, and regulatory compliance is essential for success in this position.
• Strong analytical and problem-solving skills are required to diagnose issues and implement effective solutions in a fast-paced industrial setting.
• Excellent communication skills are necessary to clearly articulate technical concepts to both engineering teams and non-technical stakeholders.

Nice to have

• Experience within healthcare waste management or medical device environments is preferred.
• Core skills should include advanced PLC programming, robotics, and machine vision.

Practical notes

This role requires travel across the USA and Canada, including mandatory travel to Taylor, Michigan, for Induction training. The position is full-time and offers a compensation range of $120,000 USD to $150,000 USD.