Senior Controls Systems Engineer
📍 Location: Waukesha, Wisconsin
🏢 Work Model: Primarily Onsite (flexible when needed for appointments, illness, or extreme weather)
💼 Employment Type: Full-Time
💰 Base Salary: $105,000 – $120,000
✈️ Travel: Occasional (primarily day trips to nearby facilities)
🎓 Education: Bachelor’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
Bachelor’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