What does a controls engineer do? A controls engineer designs, programs and troubleshoots the systems that make machines and processes run automatically. That usually means writing PLC logic, building HMI screens, setting up SCADA systems, tuning motion and process loops, and commissioning equipment on the plant floor.
If a conveyor, robot cell, packaging line or water treatment plant runs without someone flipping every switch, a controls engineer made that happen. It is a hands on engineering job that sits between electrical, mechanical and software work.
Key takeaways
- Controls engineers design and program automation: PLCs, HMIs, SCADA, drives, motion control and safety systems.
- Commissioning and startup support are core parts of the job, so expect real time on site.
- BLS has no single controls engineer code; the closest benchmark, electrical engineers, had a May 2025 median of $120,630.
- Most roles want a bachelor’s degree in electrical, mechanical, mechatronics or a related engineering field.
- ISA’s Certified Automation Professional (CAP) is a recognized credential for experienced automation engineers.
What does a controls engineer do day to day?
The work splits between the desk and the floor. At the desk, you design control panels, write and test logic, and document the system. On the floor, you check wiring, run I/O tests, tune loops and get the machine producing.
O*NET does not list a separate controls engineer occupation, but its mechatronics engineer profile captures much of the work, including designing systems to automate industrial tasks, applying sensors and control devices for motion control, and monitoring or calibrating industrial control systems to maximize production efficiency.
| Task | What it looks like in practice |
|---|---|
| Control system design | Selecting PLCs, I/O, drives and sensors; creating electrical schematics and panel layouts |
| PLC programming | Writing ladder logic, function block or structured text for sequences, interlocks and alarms |
| HMI development | Building operator screens for status, recipes, alarms and manual controls |
| SCADA and data | Connecting plant equipment to supervisory systems, historians and MES |
| Motion control | Configuring servo drives, VFDs and coordinated motion for robots and machines |
| Commissioning | I/O checkout, loop tuning, factory and site acceptance testing, operator training |
| Troubleshooting | Tracing faults through logic, networks and field devices to get equipment running again |
What are PLCs, HMIs and SCADA systems?
These three acronyms show up in nearly every controls engineering job description, so it helps to know what each one does.
Programmable logic controllers (PLCs)
A PLC is the industrial computer that runs the machine. NIST defines it as a solid state control system with user programmable memory for storing instructions that implement functions such as I/O control, logic, timing, counting and PID control. Controls engineers write and maintain that program.
Human machine interfaces (HMIs)
An HMI is the touchscreen or display operators use to start, stop and monitor equipment. A good HMI makes the machine easy and safe to run; a poor one creates downtime and mistakes, so screen design is a real skill.
SCADA systems
SCADA stands for supervisory control and data acquisition. NIST describes it as a computerized system that gathers and processes data and applies operational controls over long distances, with typical uses in power transmission and pipelines. In plants, controls engineers often tie PLCs into SCADA so managers can see and control multiple lines or sites.
Motion control and safety
Many roles also involve servo drives, variable frequency drives and robotics, plus safety PLCs, light curtains and interlocks that protect people working around the equipment.
What industries hire controls engineers?
Almost any business that runs automated equipment needs controls expertise. The most common employers we see include:
- Discrete manufacturing: automotive, aerospace, electronics and consumer products
- Process industries: chemicals, food and beverage, pharmaceuticals, oil and gas
- Water and wastewater utilities and municipal treatment plants
- Power generation, renewable energy and electric utilities
- Warehouse automation, material handling and packaging
- Machine builders and system integrators that design equipment for other companies
- Data centers and building automation
System integrator roles usually involve more travel and a wider variety of projects. Plant roles are more stable and focus on keeping one site running. If robotics is the part that excites you, see our take on whether robotics engineering is a good career.
Recruiter tip: When you apply, list the exact platforms you have programmed, such as Rockwell Studio 5000, Siemens TIA Portal or Ignition, and say whether you wrote the code from scratch or modified existing programs. Hiring managers screen hard on platform match, and that detail often decides who gets the first call.
How much do controls engineers make?
There is no single Bureau of Labor Statistics occupation for controls engineers. Depending on the employer, they may be reported under electrical engineers, mechanical engineers or engineers, all other. The BLS handbook figures for electrical engineers are the closest widely used benchmark.
| Benchmark (May 2025) | Median annual wage |
|---|---|
| Electrical engineers | $120,630 |
| Electronics engineers, except computer | $130,220 |
| Engineers, all other (includes mechatronics engineers per O*NET) | $122,930 |
| All engineers | $108,620 |
For electrical engineers, BLS reports that the lowest 10 percent earned less than $76,550 and the highest 10 percent earned more than $184,300 in May 2025. Among top industries, the median ranged from $105,780 in engineering services to $141,160 in aerospace product and parts manufacturing.
BLS projects overall employment of electrical and electronics engineers to grow 8 percent from 2025 to 2035, much faster than average, with about 16,300 openings each year. Treat these as proxies, since actual controls pay depends heavily on platform skills, travel and industry.
What skills and software does a controls engineer need?
| Skill area | Common tools and examples |
|---|---|
| PLC programming | Rockwell Studio 5000, Siemens TIA Portal, Mitsubishi, Omron |
| HMI and SCADA | FactoryTalk View, WinCC, Ignition, Wonderware |
| Industrial networks | EtherNet/IP, PROFINET, Modbus, OPC UA |
| Electrical design | AutoCAD Electrical, EPLAN, reading schematics and P&IDs |
| Motion and robotics | Servo drives, VFDs, robot controllers, vision systems |
| Scripting and data | Python, SQL and historians for data collection and reporting |
Soft skills matter just as much. You will explain faults to operators, negotiate scope with project managers and stay calm during a startup that is running behind. Clear documentation also saves the next engineer hours of guesswork.
How do you become a controls engineer?
BLS says electrical and electronics engineers typically need at least a bachelor’s degree in a related engineering field, and it notes that employers value practical experience such as internships and cooperative engineering programs. Controls engineers commonly come from electrical, mechanical, mechatronics or computer engineering programs.
- Earn an engineering or engineering technology degree with coursework in circuits, control theory and programming.
- Get hands on with a real or trainer PLC and build small projects with I/O, timers and an HMI.
- Look for internships with system integrators, machine builders or plant maintenance engineering teams.
- Start as a junior controls engineer, automation technician or field service engineer.
- Add certifications once you have experience.
On certification, ISA offers the Certified Automation Professional (CAP) credential, which requires meeting education and work experience requirements and passing a four hour, 175 question exam. ISA also offers the Certified Control Systems Technician (CCST) credential for technicians.
What does the controls engineer career path look like?
| Level | Typical responsibilities |
|---|---|
| Junior or associate controls engineer | I/O checkout, HMI edits, small logic changes under supervision |
| Controls engineer | Programs full machines or process areas, leads commissioning on smaller jobs |
| Senior controls engineer | Owns system architecture and standards, leads large startups, mentors others |
| Lead or principal engineer | Sets automation strategy, reviews designs, handles complex integrations |
| Manager or director | Runs a controls or automation team, budgets and project portfolios |
How is a controls engineer different from an electrical or automation engineer?
The titles overlap. An electrical engineer may design power distribution, circuits or electronics with no automation at all; see our guide to what an electrical engineer does for that side. A controls engineer focuses on how a system behaves: logic, sequencing, feedback and operator interaction.
Automation engineer is often used as a synonym, though some companies use it for broader roles that include robotics, MES or software. Instrumentation and controls engineers lean more toward process plants, specifying transmitters, valves and analyzers.
For a deeper look at pay trends, pros and cons, read our post on whether controls engineering is a good career.
Recruiter tip: If you are moving over from maintenance or electrical design, volunteer for commissioning work. Nothing builds controls credibility faster than having brought a line up from dead to running, and it is the first thing our clients ask about in interviews.
Frequently asked questions
Is controls engineering hard?
It has a steep learning curve because you need electrical, mechanical and programming knowledge at the same time. Most engineers find it gets easier once they have a few commissioning jobs behind them.
Do controls engineers travel a lot?
It depends on the employer. System integrators and machine builders often send engineers to customer sites for weeks at a time, while plant based controls engineers mostly stay at one facility.
Can you become a controls engineer without an engineering degree?
Some people move up from electrician or automation technician roles, especially at integrators. Many employers still prefer a bachelor’s degree, which BLS lists as the typical entry requirement for electrical engineers.
Which PLC brand should I learn first?
Learn whatever is most common in the plants near you. In our experience, Rockwell and Siemens show up in the most US job postings, and the core logic skills transfer between platforms.
Is controls engineering a good fit for remote work?
Partly. Programming, design and documentation can often be done remotely, but commissioning, startup and troubleshooting require you on site.
Looking for your next PLC, SCADA or automation role? Our controls engineering recruiters work with manufacturers, integrators and utilities hiring controls engineers at every level. Send us your resume and tell us which platforms you know best.
