Sr. Controls Systems Engineer

Job Summary

We are seeking a Senior Controls Engineer to join our Advanced Manufacturing team at our Corporate HQ in Waukesha, WI. In this role, you will be responsible for designing, implementing, and successfully scaling automated and semi-automated control systems using sound engineering principles and technologies. You will develop PLC code that interacts with subsystems such as conveyors, robots, Manufacturing Execution Systems (MES), machine vision, and third-party equipment. Additionally, you will conduct research and development on new technologies to address complex assembly and automation challenges impacting the quality and delivery of products.

Responsibilities

• Develop new or improved processes through the application of theoretical and practical engineering.
• Design and build factory-level and line/machine-level control standards and specifications for internal equipment development teams and external partners.
• Serve as the corporate Subject Matter Expert (SME) for plant resources on control systems programming by architecting, writing, and debugging PLC ladder logic/IPC software.
• Implement ANSI/RIA15.06/OSHA-compliant control-reliable safety systems for safeguarding robots, gantries, conveyors, and other high-volume manufacturing equipment.
• Generate aesthetically simple HMI screens for complex machinery while providing sufficient feedback for troubleshooting.
• Collaborate with IT to connect manufacturing assets to the enterprise network using established standards and guidelines.
• Stay informed of relevant technical trends and developments, incorporating them into assignments.
• Create Requests for Quotation/Proposal (RFQ/RFPs), organize cross-functional reviews of machine requirements, design, qualification, and capability, and engage machine suppliers for automated equipment design reviews and proposals.
• Travel to machine suppliers for equipment qualification, acceptance testing, and support during build events.

Minimum Qualifications

• Bachelor of Science Degree in Engineering, Computer Science, or a related discipline.
• 7 years of experience with Rockwell Logix.
• Frequent travel to other sites for support as needed (generally day trips).

Preferred Qualifications

• Expert-level experience in the design, programming, integration, and validation of controls in high-volume automated process equipment for discrete manufacturing using Rockwell Logix and Client RXi platforms.
• Experience in designing controls hardware and OT infrastructures, including a thorough understanding of Industrial Communication Protocols.
• Experience in creating technical specifications for automated manufacturing equipment, machine qualification requirements, design of experiments, and failure analysis.
• Expertise in the design of machine safety circuits and programming of safety PLCs.
• Expertise with software and SCADA platforms to support Industry 4.0 manufacturing projects, including Historians and OPC Servers.
• Experience with machine integration with common IoT platforms.
• Experience with SQL and Python/Java is a plus.
• Ability to communicate effectively in a worldwide environment.
• Previous experience with SAP or equivalent ERP.
• Experience with Fanuc robotics is a plus.

Knowledge, Skills, & Abilities

• Works independently with occasional guidance on challenging technical issues.
• Requires in-depth knowledge and/or breadth of expertise.
• Uses best practices and knowledge of internal and external business issues to improve products or services.
• Recommends solutions and best practices.
• Strong conceptualization, visualization, and creativity.
• Strong time management, prioritization, and analytical problem-solving skills.
• Solves complex problems and takes a new perspective using existing solutions.
• Strong decision-making skills.
• Represents the level at which a career may stabilize for many years or even until retirement.
• May lead cross-functional project teams and ensure success cross-functionally.
• Actively coaches colleagues with less experience.
• Offers recommendations and implements solutions, taking ownership of designs.
• Participates in standards and procedure development.
• Leads efforts to improve the financial impact of engineering activities on the business and has a thorough understanding of how other functions impact the business.

Waukesha, WI, is a vibrant community known for its rich history, excellent schools, and proximity to Milwaukee, offering a high quality of life and numerous recreational opportunities.