Controls Engineer - MA

Methods Machine Tools was established in 1958 with three employees and a handful of refurbished machines. Since then, the company has become one of the largest privately owned machine tool importers in North America. Methods designs and implements custom machining setups, including machine tool selection, automation integration, and turnkey automation cells. The corporate campus in Sudbury, Mass., comprises a showroom/technical center, which contains automation, applications, and a full range of cutting-edge machines. Methods has more than 300 employees, seven technology centers, one high precision machining center, and has installed more than 45,000 machines throughout North America.

The following position is available at our location in Sudbury, MA:

Job Summary: 

The Controls Engineer is responsible for the electrical design, systems integration, and troubleshooting of control systems for both custom automation cells and standard offerings. This role focuses on designing the necessary communication and I/O infrastructure—often utilizing ladder logic—to serve as the vital bridge between the CNC machine, robot, and other third-party integrated systems. The ideal candidate will be a primary, hands-on resource for resolving electrical and software issues during system build, debug, and installation, and will support validation efforts both in-house and at customer facilities.

Duties/Responsibilities: 

• Design and draft complete electrical control schematics for custom automation cells and standard machinery using CAD software, ensuring compliance with relevant electrical codes and standards.
• Develop, program, and manage the communication logic (e.g., ladder logic) within the machine controller to exchange critical process signals and data with integrated systems (e.g., robotic cells, measurement devices).
• Select, specify, and configure necessary electrical hardware components, including safety circuits, HMIs, sensors, and actuators.
• Serve as the primary hands-on troubleshooter for electrical wiring, component, and software-related issues for both standard products and custom cells during the build and debug phases.
• Support in-house system validation and actively assist with the commissioning and start-up of integrated systems at customer facilities.
• Travel to customer sites to support commissioning, troubleshooting, and service work as required.
• Collaborate closely with mechanical engineers, build technicians, machinists, and external robot programmers to ensure seamless system integration and functionality.
• Maintain comprehensive technical documentation, including wiring diagrams, component specifications, and control logic descriptions.

Required Skill/Abilities:

• Proficiency in electrical schematic design and drafting (CAD), with an understanding of industrial electrical standards (e.g., NFPA 79).
• Advanced proficiency in programming industrial control logic (e.g., ladder logic), specifically for I/O management and high-level machine-to-system communication.
• Exceptional hands-on electrical troubleshooting skills to diagnose and resolve complex hardware failures, wiring faults, and software integration problems quickly.
• Strong working knowledge of industrial communication protocols (e.g., Ethernet/IP, Profinet) to facilitate data exchange with third-party systems like FANUC robots.
• Ability to read, write, interpret, and modify detailed engineering drawings and documentation.
• Strong communication and collaboration skills for working effectively with various engineering disciplines and customer personnel.
• Willingness and ability to travel domestically to support commissioning and service work.

Minimum Education and Experience: 

· Bachelor’s degree in Electrical Engineering, Mechanical Engineering, Control Systems Engineering, or a related field.

· Relevant certifications (e.g., ISA Certified Control Systems Technician) are advantageous.

Supervisory Responsibilities:

· none

Travel Requirements: 

· Approximately 25% of time

Physical Requirements: 

· Prolonged periods of sitting at a desk and working on a computer.

· Must be able to lift up to 15 pounds at times. 

Additional Information

This job description is designed to provide an overview of basic skills, experiences and education required to perform the job and is not designed to cover or contain a comprehensive listing of all activities, duties, or responsibilities required of the employee to perform the essential functions of the job. In instances where educational degrees are required, the company will take into consideration factors such as additional experience, training, or certifications in lieu of specific educational requirements.

Methods Machine is an Equal Opportunity/Affirmative Action employer. All qualified applicants will receive consideration for employment without regard to sex, gender identity, sexual orientation, race, color, religion, national origin, disability, protected Veteran status, age, or any other characteristic protected by law.