Allen Bradley PLC

Senior Electrical & Controls Engineer โ€“ PLC, Automation, Capital Projects | Hybrid USA (Travel Required)

Senior Electrical & Controls Engineer

๐Ÿ“ Location: Multiple U.S. Locations (must be near a manufacturing site)
๐Ÿ  Work Model: Hybrid (flexibility when not traveling)
๐Ÿ’ผ Employment Type: Full-Time
๐ŸŽ“ Education: Bachelorโ€™s Degree in Electrical Engineering required
๐Ÿ“ˆ Experience Level: Mid-Senior
๐Ÿ•’ Experience Required: 5โ€“7+ years
โœˆ๏ธ Travel: 50โ€“75% (North America)
๐ŸŒŽ Visa Sponsorship: Not available
๐Ÿšš Relocation Assistance: Possible

Role Overview

We are seeking a Senior Electrical & Controls Engineer to lead and support capital projects across multiple manufacturing facilities.

This role is responsible for delivering end-to-end electrical and control systems engineering, from concept and design through installation, commissioning, and handover. You will play a key role in executing large-scale industrial projects and ensuring systems are safe, efficient, and aligned with operational goals.

Key Responsibilities

Capital Project Delivery

  • Lead electrical and controls engineering for capital projects ($1Mโ€“$15M range)

  • Develop:

    • Scope documents

    • Engineering designs and calculations

    • Cost estimates and schedules

    • Technical specifications

  • Manage projects from concept through execution, commissioning, and handover

Electrical & Controls Engineering

  • Design and implement:

    • Power distribution systems

    • Control systems and automation solutions

  • Specify and source equipment such as:

    • Switchgear, transformers, MCCs

    • Drives, PLCs, HMIs, relays, circuit breakers

  • Perform electrical system analysis and calculations

  • Ensure compliance with industry standards and safety requirements

Project & Contractor Management

  • Lead and coordinate:

    • External engineering consultants

    • Vendors and suppliers

    • Installation contractors

  • Manage procurement lifecycle from RFQs to installation and warranty support

  • Oversee commissioning, startup, and training for plant teams

  • Manage change control (MOC) processes

Safety & Compliance

  • Apply and promote NFPA 70E electrical safety standards

  • Lead safety initiatives related to electrical and control systems

  • Ensure all systems meet required regulatory and operational standards

Cross-Functional Collaboration

  • Partner with:

    • Operations

    • Maintenance

    • Engineering teams

    • Procurement and project management

  • Provide subject matter expertise (SME) on electrical and controls systems

  • Support both plant-level projects and enterprise initiatives

Project Ownership (Controls-Focused Projects)

  • Take full ownership of smaller projects (typically <$5M)

  • Act as Electrical & Controls Lead on larger initiatives

  • Manage:

    • Budgets and forecasts

    • Schedules and deliverables

    • Stakeholder communication

Required Qualifications

  • Bachelorโ€™s degree in Electrical Engineering

  • 5+ years of experience in controls/electrical engineering within manufacturing

  • Strong experience with:

    • Control systems and automation technologies

    • Electrical system design

  • Hands-on expertise with:

    • Allen-Bradley PLCs and HMIs (including programming)

  • Proficiency in AutoCAD

  • Demonstrated experience managing capital projects ($500Kโ€“$2M+)

  • Strong analytical, problem-solving, and communication skills

Preferred Qualifications

  • Experience with:

    • 480V and 4160V power distribution systems

    • MCCs, switchgear, and industrial power systems

  • Background in continuous and/or discrete manufacturing environments

  • Experience managing multi-site or large-scale industrial projects

Key Competencies

  • Strong project management and execution skills

  • Ability to manage multiple projects simultaneously

  • Proven ability to influence cross-functional teams

  • High level of initiative and ownership

  • Strong collaboration with internal and external stakeholders

Ideal Candidate

The ideal candidate will:

  • Have strong experience delivering electrical and controls projects in manufacturing environments

  • Be comfortable acting as both:

    • Technical expert (E&C lead)

    • Project owner (for smaller projects)

  • Thrive in a hands-on, plant-facing role

  • Be capable of managing complex, multi-site capital projects

  • Be open to frequent travel (50โ€“75%)

Screening Questions

  • Do you hold a Bachelorโ€™s degree in Electrical Engineering?

  • Do you have project engineering or project management experience?

  • Are you open to travel (40โ€“60%+)?

Additional Information

  • This role supports a high volume of active and upcoming capital projects

  • Acts as a critical technical resource across multiple manufacturing facilities

  • Opportunity to lead impactful projects driving operational performance and growth

 

Senior Controls Systems Engineer โ€“ PLC, Robotics & Industrial Automation | Wisconsin

Senior Controls Systems Engineer

๐Ÿ“ Location: Waukesha, Wisconsin
๐Ÿข Work Model: Primarily Onsite (flexible when needed for appointments, illness, or extreme weather)
๐Ÿ’ผ Employment Type: Full-Time
๐Ÿ’ฐ Base Salary: $105,000 โ€“ $120,000
โœˆ๏ธ Travel: Occasional (primarily day trips to nearby facilities)
๐ŸŽ“ Education: Bachelorโ€™s Degree in Engineering, Computer Science, or related field preferred

Role Overview

A leading advanced manufacturing organization is seeking a Senior Controls Systems Engineer to join its Advanced Manufacturing team.

This role focuses on designing, implementing, and scaling automation and controls systems across manufacturing operations. The engineer will develop PLC programs that interact with robotics, conveyors, machine vision, MES systems, and other automated equipment.

This position plays a critical role in improving automation capability, production quality, and operational efficiency across manufacturing sites.

Key Responsibilities

Automation & Controls Development

  • Design and implement automated and semi-automated control systems

  • Develop PLC code interacting with:

    • Conveyors

    • Industrial robots

    • Manufacturing Execution Systems (MES)

    • Machine vision systems

    • Third-party equipment

  • Build scalable and maintainable control architectures

Controls Engineering Leadership

  • Act as a subject matter expert for plant control systems

  • Mentor machine builders, automation vendors, and internal engineering teams

  • Lead technical direction for automation projects

Industrial Automation Programming

  • Architect, write, and debug PLC ladder logic and IPC software

  • Develop well-structured, documented, reusable code

  • Create intuitive HMI interfaces for complex manufacturing equipment

Manufacturing Automation Integration

  • Integrate controls with:

    • Robotics

    • Machine vision

    • Part tracking systems

    • MES platforms

  • Work with IT teams to connect manufacturing assets to enterprise networks

Machine Safety & Compliance

  • Implement safety systems compliant with:

    • ANSI

    • RIA

    • OSHA

  • Design and program safety PLC systems protecting robotics and automated equipment

Capital Equipment Development

  • Create RFQs/RFPs for automated equipment

  • Lead equipment design reviews and technical evaluations

  • Travel to supplier sites for:

    • Equipment validation

    • Factory acceptance testing

    • Build event support

Legacy System Modernization

  • Identify legacy control systems via risk assessment

  • Develop remediation strategies

  • Execute system upgrades and modernization initiatives

Required Qualifications

  • Bachelorโ€™s Degree in Engineering, Computer Science, or related discipline

  • 7+ years of experience with Rockwell Logix PLC platforms

  • Strong experience developing controls for automated manufacturing systems

  • Experience programming PLCs interacting with robotics, conveyors, and automated systems

  • Strong troubleshooting and debugging capability

Preferred Experience

  • Expert experience with:

    • Rockwell Logix platforms

    • GE RXi control systems

  • Experience designing controls hardware and OT infrastructure

  • Knowledge of industrial communication protocols

  • Experience designing automated manufacturing equipment specifications

  • Experience with:

    • OPC servers

    • Industrial historians

    • SCADA platforms

    • Industry 4.0 manufacturing systems

  • Experience integrating IoT platforms with factory equipment

  • Experience with SQL, Python, or Java

  • Familiarity with ERP platforms such as SAP

  • Experience with Fanuc robotics

Ideal Candidate Profile

The ideal candidate is a hands-on automation expert who:

  • Has deep experience programming Rockwell / Allen-Bradley controls

  • Has led automation implementations in high-volume manufacturing

  • Can integrate robotics, MES, vision systems, and automated equipment

  • Is comfortable mentoring vendors and internal engineers

  • Can troubleshoot complex manufacturing systems under real production conditions

  • Has strong problem-solving, leadership, and technical communication skills

Key Skills

  • PLC Programming (Rockwell Logix)

  • Industrial Automation

  • Robotics Integration

  • Machine Safety Systems

  • SCADA / Industry 4.0

  • Industrial Networking

  • MES Integration

  • Controls Architecture

  • HMI Development

  • Automation Project Leadership

Benefits Overview

  • Comprehensive health benefits (medical, dental, vision)

  • Retirement savings plan (401k)

  • Modern facility with onsite amenities

  • Employee engagement programs and events

  • Product discount programs

  • Strong culture focused on innovation and teamwork