Automation Controls Engineer

WHO WE ARE LOOKING FOR

We are looking for an Automation Controls Engineer to develop and implement the control software for our cutting-edge automation projects. In this role, you will program PLCs and HMIs, create motion control sequences, and integrate safety and sensor feedback systems to ensure our machines and scenic elements operate reliably and safely. You will be responsible for leading in-house software testing and on-site commissioning of automation systems, tuning performance and making real-time adjustments to meet both creative and technical requirements.

Automation Controls Engineers are at the core of bringing our automation systems to life through code. You will be deeply involved from the design phase through final show delivery, collaborating closely with the Automation Systems Designer to align on overall system behavior and with the Automation Design Engineer to ensure the hardware and software work together seamlessly. You will conduct simulations and thorough testing (Factory Acceptance Testing) to validate your control programs before deployment, and you will be a key player on site during installations – fine-tuning control parameters and working directly with clients and operators to achieve the desired show effects.

As part of our Automation team, you will also contribute to documentation and operator training, ensuring that our clients can confidently run the systems we deliver. This role requires creativity, precision, and a proactive mindset to anticipate and solve problems in high-pressure environments. Your goal will be to promote a culture of accountability, safety, and continuous improvement by delivering robust, user-friendly control systems and supporting them through successful commissioning.

YOUR DAY TO DAY

- Program and develop PLC software for automation systems, using platforms such as Beckhoff TwinCAT (IEC 61131-3 structured text) or other industrial control software (Allen-Bradley, Siemens, Stage one’s Q-motion, XM-automation etc. as required by the project).

- Design and implement HMI (Human-Machine Interface) screens or show control interfaces that allow operators to control and monitor the automation system effectively.

- Create and refine motion control sequences and cue logic for moving elements (e.g. lifts, turntables, winches), ensuring movements are synchronized, smooth, and meet creative timing requirements.

- Implement and test safety interlocks and fail-safe logic in software – for example, ensuring limit switches, E-stop circuits, and safety zones are correctly integrated into the control program.

- Integrate data from sensors and feedback devices (encoders, load cells, proximity sensors) into the control algorithms to achieve precise control and automation cues that react to real-time conditions.

- Conduct software simulations and bench tests to validate the PLC/HMI programs before equipment is installed (using digital twins or test setups when available).

- Lead the software aspect of Factory Acceptance Tests, demonstrating the functionality of the control system to internal stakeholders and clients, and making any necessary adjustments based on feedback.

- Travel to project sites for Site Acceptance Testing and commissioning, where you will upload and tune software on actual equipment, execute test runs, and optimize performance in the real environment.

- Troubleshoot and resolve control system issues during installation and rehearsals, working closely with the Automation Controls Integrator and technicians to identify whether problems stem from software, hardware, or sensors.

- Adjust programming in response to creative team input during on-site programming sessions, balancing artistic requirements with equipment safety and capabilities.

- Establish and maintain version control for all software (using tools like Git or other version repositories), and document changes thoroughly to keep a clear history of program modifications.

- Create end-user documentation such as operational manuals, software diagrams, and training materials to guide operators and maintenance technicians in using the system.

- Stay up-to-date with the latest developments in control technology (new PLC hardware, motion controllers, software libraries, etc.) and suggest improvements or upgrades that could enhance our systems’ performance or reliability.

YOUR QUALIFICATIONS

- Bachelor’s degree in Electrical Engineering, Computer Engineering, Automation Technology or a related field; or equivalent experience in programming industrial or theatrical automation systems.

- 3+ years of hands-on experience developing and programming PLC-based control systems (experience with Beckhoff TwinCAT, Allen-Bradley/Rockwell, Siemens, or similar automation platforms is highly desirable).

- Proficiency in programming user interfaces/HMIs and understanding how operators interact with automation systems (experience with custom show control interfaces is a plus).

- Strong knowledge of motion control principles – including understanding of servo motors, VFDs, motion profiles, acceleration/deceleration tuning, and synchronization of multi-axis systems.

- Familiarity with industrial safety systems and standards – able to implement software logic that respects safety circuits, emergency stops, and operational interlocks.

- Experience with on-site commissioning and troubleshooting of automated systems; able to remain calm and systematic in diagnosing issues under pressure (for example, differentiating between a sensor fault vs. a programming bug).

- Solid understanding of network communications and fieldbuses (EtherCAT, Ethernet/IP, Modbus, CANopen, etc.) used to connect PLCs, remote I/O, and devices.

- Ability to read electrical schematics and mechanical drawings to understand how the software needs to interact with hardware components.

- Experience using software version control and issue tracking to manage code changes and collaborate with other developers or engineers.

- Excellent problem-solving skills and attention to detail, with a creative mindset for overcoming technical challenges in innovative ways.

- Strong teamwork and communication skills – able to work closely with hardware engineers, creative designers, and client teams, and convey complex information clearly.

- High level of professionalism and a proactive attitude toward learning new technologies and improving processes.

- Ability to handle multiple projects or tasks simultaneously and adapt to changing priorities and deadlines.

- Willingness to work non-traditional hours (evenings, weekends) during critical testing and show programming periods.

- Must hold (or have a willingness to obtain) an OSHA 30-hour Construction certification dated within the last five (5) years.

- Willingness to travel (approximately 20%) for installations, show support, and client meetings, and ability to obtain a passport for international travel.

YOUR WORK ENVIRONMENT

This position is based in our home office in Henderson, Nevada, with significant collaboration in our shop and occasional extensive periods on-site during project installation and show programming. Anticipated travel is estimated at a 20% level. The schedule can vary and will include intensive on-site commissioning periods as well as standard office hours for development and testing.

OUR OFFER TO YOU

- Base salary.

- 100% paid premium for Medical Insurance Plan for employee.

- 100% paid premium for $25,000 Basic Life Insurance Plan for employee.

- 50% paid premium for Dental Insurance Plan for employee.

- 50% paid premium for Vision Insurance Plan for employee.

- 401(k) retirement plan.

- Unlimited PTO (Paid Time Off).

- All federal holidays paid.

- Skills development activities and opportunities for career advancement.

- Personal Enrichment Program.