Top 20 Interview Questions & Answers for Controls Engineer Roles – 2025

Getting ready for an interview for a controls engineer position? As a controls engineer, you'll be responsible for designing, developing, and maintaining control systems for various industrial processes. This list of questions and answers will help you demonstrate your technical knowledge, problem-solving skills, and experience with control theory and systems integration.

General Questions

• 1. Tell us about your experience in controls engineering.
  As a controls engineer, I have over 5 years of experience in designing, implementing, and maintaining control systems for various industrial processes. I have worked with various software and hardware programming languages, such as PLC, HMI, and SCADA systems.
• 2. What motivated you to become a controls engineer?
  I have always had a strong interest in automation and technology. In college, I took several courses in control theory and found it fascinating. I knew then that I wanted to pursue a career in controls engineering, where I could combine my passion for technology with problem-solving skills.
• 3. How do you stay updated with the latest industry developments and technologies?
  I regularly attend workshops, seminars, and conferences related to controls engineering. I also follow industry publications and online forums to stay informed about the latest trends and developments. I believe in continuous learning and always strive to expand my knowledge and skills.
• 4. How comfortable are you with working on interdisciplinary projects?
  I am very comfortable working on interdisciplinary projects. In fact, I believe that collaboration between different teams and disciplines is crucial for the success of any project. I have experience working with electrical, mechanical, and software engineers, as well as with clients from various industries.

Technical Skills & Experience

• 5. Can you walk us through your experience with PLC programming?
  I have extensive experience in PLC programming, including Allen-Bradley, Siemens, and Omron systems. I have developed programs for custom automation projects, as well as for machine control and process control applications. I am also familiar with ladder logic, structured text, and function block programming languages.
• 6. How do you troubleshoot and resolve issues with control systems?
  I follow a systematic approach to troubleshooting by first identifying the root cause of the issue. I use various tools and techniques, such as analyzing system logs, checking wiring, and using diagnostic equipment, to pinpoint the problem. I then work to develop a solution, test it, and implement it once it has been verified.
• 7. Share an example of a successful project where you had to design a complex control system.
  In my previous role, I designed a control system for a bottling plant that required synchronizing multiple machines, including filling machines, capping machines, and labeling machines. I utilized a PLC with motion control capabilities and developed a program that ensured all machines worked together seamlessly. The project was completed on time, and the client was extremely satisfied with the results.
• 8. What experience do you have with HMI and SCADA systems?
  I have experience designing and programming HMI and SCADA systems for various industrial processes. I have worked with various software, including FactoryTalk View and Wonderware InTouch, to create user-friendly interfaces for controlling and monitoring equipment and processes. I am also familiar with OPC communication protocols.

Behavioral Questions

• 9. How do you approach a project with tight deadlines and a high level of complexity?
  When faced with a challenging project, I start by breaking it down into smaller, manageable tasks. I prioritize these tasks based on their importance and work on them one at a time. I also make sure to communicate regularly with my team to ensure we stay on track and address any issues as they arise.
• 10. Share a situation where you encountered a problem with a control system and how you resolved it.
  In my previous role, we had a situation where a control system malfunctioned, causing production delays. I quickly identified that there was a faulty sensor, and instead of replacing it immediately, I came up with a solution to bypass the sensor temporarily while we sourced a new one. This minimized downtime and allowed us to continue production until the sensor was replaced.
• 11. How do you ensure technical documentation is accurate and up-to-date?
  I know how vital accurate technical documentation is, especially for complex control systems. Whenever I complete a project, I make sure to document my work thoroughly. I also regularly review and update documentation as needed. Additionally, I involve other team members in reviewing and confirming technical documentation to ensure its accuracy.
• 12. Tell us about a time you had to handle a difficult client and how you resolved the situation.
  I once had a client who was demanding and had unrealistic expectations about project timelines. I made sure to listen to their concerns and communicate effectively to manage their expectations. I also provided regular updates on the project's progress, which helped establish trust and ultimately resolved the situation.

Situational Questions

• 13. How would you handle a situation where a control system malfunctions in the middle of production?
  In such a scenario, I would first make sure to take all necessary safety precautions to avoid any injuries or damage. Then, I would start troubleshooting the issue immediately, utilizing my technical knowledge and tools to identify the cause of the malfunction. I would also prioritize fixing the issue while minimizing downtime.
• 14. You discover that a control system you designed has a flaw that could potentially cause safety hazards. How do you address this situation?
  In this case, the safety of the workers and equipment is of the utmost importance. I would first inform my supervisor and then work on a solution to fix the flaw as soon as possible. I would also prioritize testing and verifying the fix to ensure it is effective and safe.
• 15. How do you handle conflicting requests from different teams or stakeholders regarding a control system design?
  In such a scenario, I would evaluate the requests objectively and work to find a balance between what is technically feasible and what meets everyone's needs. I would also communicate openly with all parties involved and try to find a compromise that would satisfy most stakeholders.
• 16. Describe a time when you had to make a quick decision in a high-pressure situation.
  In my previous role, there was an unexpected power outage while we were testing a new control system. I had to make a quick decision on how to safely shut down the system. I immediately halted all operations and worked with my team to contain the situation and shut down the system properly.

Cultural Fit Questions

• 17. What values do you think are important for a team to succeed?
  I believe that communication, collaboration, and respect are vital for a team to succeed. Clear communication ensures everyone is on the same page, collaboration utilizes everyone's strengths, and respect fosters a positive and productive work environment.
• 18. How do you handle criticism or feedback from colleagues or superiors?
  I am open to constructive criticism and feedback as I see it as an opportunity to improve and grow. I listen carefully to the feedback and take it into consideration when making changes or improvements. I also make sure to communicate my appreciation for the feedback and thank the person providing it.
• 19. How do you prioritize and manage your workload?
  I prioritize my workload based on deadlines and urgency. I also make sure to communicate with my team and manager to understand their expectations and prioritize tasks accordingly. I also utilize productivity techniques, such as creating to-do lists and breaking down tasks, to manage my workload effectively.
• 20. What motivates you to perform well in your job?
  I am motivated by challenging projects, continuous learning opportunities, and being able to see the results of my hard work. I also value a positive and supportive work environment, which motivates me to contribute my best and achieve success as a team.