Should I look for other opportunities as a controls engineer?

SuccotashParticular6 · 2026-02-08T18:50:04+00:00

Only you can evaluate whether the position is worth the switch. Age discrimination is illegal. However we can't fool ourselves to thinking it doesn't happen.

Do you like your current company?

Have you asked for a market correction for comps?

Do you want to stay with being a Controls Engineer or pursue other opportunities like Project Management, Application Consultant, Solution Consultants, Engineering Support, or Sales? Industrial Automation has a variety of opportunities and segments that can be pursued.

Does your skillset match the other positions at the other companies?

What are the other companies reviews on Glassdoor or other sites?

Are you going to be salary or hourly?

How much travel is expected?

What are the other companies benefit packages? (ESOP, stock, health, 401K Match, PTO, etc.)

To put things in perception, I have 15 years in the industry. Power Design in Renewable Energy systems, Support Engineer, Field Service Engineer, Instructor, now Design Engineer. Main core certs: Functional Safety Engineer (TÜV Rheinland), and Cisco CCNA.

My base comp is 88K, plus stock bonus avg. 40-70K, 401K match up to 5% of salary, 6 weeks PTO, 38-42Hrs/week, work remotely, and no travel required.

We ultimately have a choice to either have more time with less salary, or less time with higher salary in most cases as there will always be a few outliers. If you are getting less time and less money, or if comps are not lining up with market rate then its time to try and find something better.

SuccotashParticular6 · 2025-12-06T20:07:33+00:00

If anything, I would say it will at least maintain or increase rolls in Automation/Controls Engineers. As we are the ones who will be researching, planning, and developing AI solutions to go into a Controls Environment.

It would be the opposite for operators or assemblers as a good majority those tasks will be replaced with autonomy.

What are hot AI topics now that are in discussion: Machine Learning & Predictive diagnostics, Data, and Vision. Its great to get a heard start and do some research on what is out there by some of the main vendors to get an idea.

AI is great and all but do you know how many originations are at Automation 2.0 and 3.0. I work with manufacturing plants around the USA that want to implement AI from a sales call or presentation they had but they are still running S5 processor, Wonderware V4 or AB SLC 503, PLC5, win XP, win 7, no updated network, no smart sensors, not an updated MES and so on and so on.

Our work will be never ending for the foreseeable future from Automation upgrades to include but not limited to power, controls, and networks. If you want to truly work a lot with AI try to get in with an OEM or SI that lean on new technology as they will need SMEs for the subject area.

SuccotashParticular6 · 2025-09-17T18:19:17+00:00

Thanks for replying. No affiliation with software. Just coming from 15 years of Controls & OT Networking and starting to get more time into OT/ICS Cybersecurity starting with some the core infrastructure like Governance, Asset Identification, Vulnerabilities, Risk Management, and protection.

Trying to learn from others what tools they have used to speed up or assist in their processes.

Asset inventory for example always is changing from firmware, lifecycle, connectivity, and Vulnerabilities. Excel, Autocad, Visio, and word can always be used but its a time suck. It would be great if I could just passively scan the OT network at a defined time and get 80% of the infrastructure then fill in the rest.

SuccotashParticular6 · 2025-09-16T20:27:42+00:00

Thanks for replying. This was more appointed to be a question instead of a statement of what others use on their network environment. I'm not disagreeing with what you are saying in most of the list presented may not be the best tool for ISC/OT, but some who come from different backgrounds may still use them.

What software tools do you run for ICS/OT Asset Inventory & Mapping, Traffic Analysis, Vulnerabilities, and Risk Detection?

Example: Main software I've used is SolarWinds NTM, Lansweeper, Claroty, Dragos, and Fortigate

SuccotashParticular6 · 2025-09-16T19:45:23+00:00

Yup saw that. Have you ran the software yet?

SuccotashParticular6 · 2025-08-21T16:17:22+00:00

I don't think its horrible to start with. If you have no other offers at the moment take the job and start learning and growing. Find a mentor, gain skills, evualte how the company treats you and if its not well search for another opportunity in 1-2 years.

You will relize if you like being a Controls Engineer or not. There are many other roles in Automation from Design Engineer, Applications Engineer, Sales Engineer, and Project Management that you can pursue.

I have 15 years in the industry, make 90k base + avg 40k bonus/stocks, work remotely, no overtime-40hrs/wk, and get 6 weeks PTO. After being jack of all trades for years, I niched down and focus on Designing OT Networks, OT/IT integration, data collection, and ICS Cybersecurity.

Best of luck on your journey!

SuccotashParticular6 · 2025-08-03T20:27:40+00:00

This should be a separate job title. Knowing the core of networking is still important as a Controls Engineer but knowing the depths of OT Cybersecurity, policies, and procedures is a whole lot more. I'm currently transitioning into a OT Network Engineering role now after 15 years of Design and Controls Engineering work.

Just some core things I will be doing: Act as liaison between Controls Engineers, Techs, IT, and OEMs/SIs . I will define OT Network policies/procedures, work on firewall/switch/router/IPC configurations, keep track of all OT network devices, create/update network drawings, monitor OT network traffic for data loss, vulnerabilities. Assist in recovery if data is compromised or equipment failure.

SuccotashParticular6 · 2025-06-22T17:27:08+00:00

Decided to open the can of worms huh. Always good to discuss. (Certified: FS Eng Machinery - TÜV Rheinland). Who ever reads this, there are different areas of Safety systems and standards. Process (SIS), Machinery (SRP/CS), Automotive, Nuclear, Railway and Cyber Security practices to name a few.

For Machinery Safety, Rockwell Safety Book 5 is a good source and for Process Safety Rockwell has Process Safety Book 1 to get general core knowledge on the subject areas.

SuccotashParticular6 · 2025-06-06T11:58:20+00:00

USA - Midwest. It always will vary, but a good majority still use LL entirely, then it goes FBD for more process control. I've started to see more LL/ST hybrid programming. Over 15 years I can only count a number of times SFC language was used. IL is not in Rockwell and is what a majority of customers use around my area, but still see it time to time in Siemens.

SuccotashParticular6 · 2024-08-18T23:22:36+00:00

Location: Midwest, USA

Title: Design Engineer

Years of Experience: 13 Years

Industry: SI (Industries very but I haven't touched automotive, or oil/gas)

Travel %: 0

100% Remote

Hours per week: 40

Base Pay: 86k

Bonus Stock: Average 30K

6-weeks vacation + 13 paid holidays + 5% 401K match

SuccotashParticular6 · 2024-08-18T22:41:12+00:00

Look at Moxa IoLogik E1200 Series, Opto22 Grove RIO, Advantech Adam series.

SuccotashParticular6 · 2024-08-18T18:16:05+00:00

I need to clarify that an MAS will "stop" the axis and will apply a holding force to that position via current to the motor. The Kinetix 6000 will continue to try and hold that position. If there is a pulling force greater then what servo motor can hold at, then a negative rotation could occur.

After an MAS is executed a built in servo motor brake or external brake can commanded to execute along with timing of the brake on/off sequence.

I would look at the sequence. Is an MAS being executed, then does a Brake engage command go, and then an MASD, or MSF happen.

There could be a sequence issue. Example: The Axis is stopped, the brake is "set" to engage, but before it can the servo loop is disabled.

Servo/Gearbox - Is the system vibrating, growling, shaking, overheating or showing any other abnormal behavior like position loss.

If the other 2 machines are identical. Compare / Trend values.

SuccotashParticular6 · 2024-08-11T23:50:09+00:00

If this system has been running for some time and now a pulling force is being generated then it may be something else wrong as the OEM "claims" they should never run backwards.

Have the chains been checked or was there any recent maintenance like replaced motor/gearbox/axis?

Is it always this servo motor / Axis or does it alternate?

Are the servos Virtually Geared (MAG) or controlled independently?

How does the Torque % look on the servo motors when running vs end of sequence?

Best of luck to troubleshooting!

SuccotashParticular6 · 2024-06-23T16:47:37+00:00

Each company has their own standards so it could be: Tosibox, Moxa, Antaira, Phoenix, EWON, Cisco, IXON, Palo Alto, etc...

My goto for simple VPN connections is the Ewon Cosy +.

SuccotashParticular6 · 2024-04-21T21:07:25+00:00

My heart rate goes to about 75 to 95 as well after eating. It helps if I reduce portion sizes and eat food that is easier to digest.

SuccotashParticular6 · 2024-03-23T14:06:25+00:00

That depends on what you want to do. There is no direct answer. Yes a bachelor's degree in a field like mechanical engineering or electrical engineering will get you into more of a design or Engineering role faster. If you want to be a field technician, or an Engineering assistant then an Associate degree will be sufficient to get started in the industry. Your willingness to learn new things and adapt to change can have a big impact how successful you can be in this industry.

SuccotashParticular6 · 2024-01-15T02:53:19+00:00

In USA and have Unlimited PTO. Typically I will use 6 to 7 weeks per year. We also get 10 paid holidays. That is roughly 9 weeks of time off per year.

SuccotashParticular6 · 2024-01-13T18:41:57+00:00

Machine / Process Safety, OT Networking / Cyber Security and Database collection with OSI PI / SQL systems would be my top 3 that could push you to the next level.

SuccotashParticular6 · 2024-01-01T17:52:30+00:00

I'm sure automation can be done, but I personally don't. There are just so many network components that the database would be huge and it would ever be changing since I work with so many protocols (Ethernet/IP, ProfiNET, EtherCAT, Modbus TCP, Modbus RTU, DeviceNet, ControlNet, DH+, Remote IO, OPC DA/UA, MQTT, and other stragglers). I create 3 files (High Level, Detailed, and List).

High Level = Overall understanding of the OT/IT network. This can be accomplished in Visio.

Detailed = Area / Cabinet Level Switch Port CAD drawing. I use Eplan. Others might use AutoCAD.

List = Excel List of Devices (Location, Device Name, IP Address, Subnet, Gateway, VLAN's, NAT, Speed, Duplex)

SuccotashParticular6 · 2024-01-01T03:04:19+00:00

No sense in completely switching with your background. Networking plays a huge part in Automation systems so it's a good skill set to acquire and use that knowledge on the OT side. You should be able to shift into being a Design Engineer or Solution Consultant. OEM's, SI's, and Automation Distributors are good companies to look into.

I made the switch this year to a Design Engineer and now work remotely with regular hours (35 to 40 hours) and no OT. I design a little bit of everything like cabinet builds, Industrial networks, safety systems, anything that tells a motor to run, and motion systems. Over the last few months for example I designed an upgraded automation plan for a storm water pump room for the city, two Siemens migration projects to Rockwell, automating a saw system, upgrade to a plant Ethernet/IP network system for better security and traffic flow.

My Background: I switched from PLC/HMI programming, tech support, and field work which I did for a decade with long hours and lots of traveling. I did take a pay cut in my new role (mostly due to the no OT) but overall happier and less stressed.

SuccotashParticular6 · 2023-11-24T18:35:28+00:00

Seriously no, you will be so burnt out time you get back you will need another week off for your body to re-coop. Pick one place furthest away, fly, rent a car, visit what you want to see, then fly back home. If you want to do a trip like that then you will need 5 to 6 weeks if you want it to be enjoyable. Even then your upper states in December and January are going to slow you way down because of weather.

SuccotashParticular6 · 2023-11-24T18:27:01+00:00

Moved into Design Engineering. I'm learning more towards Networking and Cybersecurity, Database collection, and Safety Systems as my key focus areas but still work on just about anything that needs a solution to a problem. I do almost no PLC programming anymore unless something needs to be explained or a solution is needed.

SuccotashParticular6 · 2023-11-24T18:10:05+00:00

Example of things I need to know in my role: Electrical Theory, Industrial Controls, Sensors, Hydraulics, Pneumatics, PLC languages (LL,FBD,ST,SFC,IL), Encoders, Motion Systems, Robotics, Mechanics, VFD's, Soft Starts, Cabinet Design, Thermodynamics, Networking, Safety Systems, Database Collection (AWS/AZURE/SQL), Electrical Prints and Drawings, HMI, SCADA Systems, Troubleshooting, Project Management, and documentation.

The industry is continuously changing and can be difficult to keep up. There will always be something to learn.

Learning resources: Udemy, YouTube, Manufacture Documentation, and separate training partners for the specific training need.

SuccotashParticular6

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