Electrical Controls Engineer

Controls Engineer – Waukesha, WI

Controls Engineer

📍 Location: Waukesha, Wisconsin
🏭 Manufacturing Environment
💼 Full-Time | Onsite
🚚 Relocation Assistance: Available
🚫 Visa Sponsorship: Not Available (Current or Future Sponsorship Not Supported)

Overview

A global manufacturing leader is seeking a Controls Engineer to support plant operations through the design, development, implementation, and troubleshooting of automated manufacturing and testing systems.

This role is ideal for an experienced controls professional who can independently design PLC systems from scratch, support production equipment, develop testing solutions, and drive continuous improvement initiatives across manufacturing operations.

Key Responsibilities

Controls & Automation Engineering

  • Design, program, and troubleshoot PLC and HMI systems.

  • Develop testing protocols, data collection programs, and test equipment specifications.

  • Support production equipment, electrical systems, and automated test platforms.

  • Develop interfaces between SQL databases and production systems.

  • Support installation, validation, commissioning, and maintenance of manufacturing equipment.

Manufacturing Support

  • Troubleshoot equipment and controls issues to minimize downtime.

  • Perform root cause analysis and corrective actions.

  • Support continuous improvement, Lean, and Six Sigma initiatives.

  • Identify and implement process improvements to improve productivity and quality.

Project Engineering

  • Lead or support capital equipment projects.

  • Develop Capital Appropriation Requests (CARs).

  • Create project goals, budgets, schedules, and work breakdown structures.

  • Support change management initiatives using structured methodologies such as ADKAR.

Safety & Compliance

  • Ensure compliance with OSHA and electrical safety requirements.

  • Identify and mitigate safety risks associated with testing and manufacturing equipment.

  • Promote a zero-incident safety culture.

Required Qualifications

Education

  • Bachelor’s Degree in Engineering from an accredited institution.

Experience

  • Minimum 5 years of Controls Engineering or Test Engineering experience in a manufacturing environment.

  • Experience designing PLC systems from the ground up.

  • Experience supporting automated production and testing equipment.

Technical Skills

  • PLC Programming

  • HMI Programming

  • SQL Database Integration

  • Rockwell Automation Software:

    • RSLogix 5

    • RSLogix 500

    • RSLogix 5000

    • Studio 5000

    • FactoryTalk View ME

    • FactoryTalk View SE

  • Visual Basic / Visual Studio

  • Microsoft Applications

Must-Have Requirements

✔ Bachelor's Degree in Engineering
✔ 5+ Years Controls/Test Engineering Experience
✔ Ability to Design PLC Systems from Scratch
✔ Rockwell Automation Software Experience
✔ PLC & HMI Programming Experience
✔ Understanding of Safety Systems Design
✔ Experience Supporting Manufacturing Equipment & Test Systems
✔ No Current or Future Sponsorship Requirements

Preferred Qualifications

  • NI LabVIEW

  • NI TestStand

  • Ignition (SCADA)

  • Lean Manufacturing

  • Six Sigma Methodologies

  • Root Cause Analysis (8D, PFMEA, A3, Pareto, Control Charts)

  • Project Management Experience

Ideal Candidate

The ideal candidate is a hands-on Controls Engineer with strong manufacturing automation experience who can independently design and support PLC-based systems while driving plant efficiency and reliability.

They will have:

  • Strong Rockwell Automation expertise.

  • Experience developing controls for production and test equipment.

  • Ability to troubleshoot complex electrical and automation systems.

  • Strong SQL and programming capabilities.

  • Experience implementing continuous improvement initiatives.

  • Excellent collaboration and problem-solving skills.

Candidate Snapshot

Requirement

Details

Education

Bachelor's Degree in Engineering

Experience

5+ Years Controls/Test Engineering

Industry

Manufacturing

Seniority

Mid-Senior Level

PLC Design

Must Build PLCs from Scratch

Rockwell Experience

Required

Travel

None

Relocation

Available

Sponsorship

Not Available

Screening Questions

  1. Can you design and build a PLC system from scratch?

  2. Do you have at least 5 years of Controls/Test Engineering experience?

  3. Do you hold a Bachelor's Degree in Engineering?

  4. Do you have experience with Rockwell software (RSLogix, Studio 5000, FactoryTalk)?

  5. Do you have PLC and HMI programming experience?

  6. Have you supported the design, development, installation, and troubleshooting of production equipment?

  7. Do you have experience with Visual Studio, SQL, and Microsoft applications?

  8. Are you authorized to work in the U.S. without current or future sponsorship?

Nice-to-Have Experience

  • NI LabVIEW & TestStand

  • Ignition SCADA

  • Lean / Six Sigma tools

  • Capital project execution

  • Manufacturing test system development

  • Change management methodologies (ADKAR)

Why Consider This Opportunity?

  • Join a global manufacturing organization with a strong reputation for innovation and stability.

  • Work on advanced automation and testing systems.

  • Drive impactful plant-wide improvements and modernization projects.

  • Excellent career growth opportunities within engineering and operations.

  • Relocation assistance available for qualified candidates.

 

Controls Engineer – Orlando, FL | PLC, Automation & System Integration

Controls Engineer

📍 Location: Orlando, Florida
🏢 Work Model: Onsite – 5 Days/Week
💼 Employment Type: Full-Time

💰 Compensation & Benefits

  • Salary Range: $111,000 – $140,000

  • Limited relocation assistance available

  • Full-time position

  • No visa sponsorship available

🚀 Overview

A leading industrial automation and systems integration organization is seeking a Controls Engineer to support large-scale automation and control system projects in Orlando, FL.

This role is responsible for full lifecycle controls engineering including:

  • Electrical and controls system design

  • PLC/DCS programming

  • Electrical panel design

  • Power calculations

  • Safety system implementation

  • Network architecture

  • System integration

  • Installation & commissioning support

The ideal candidate is a technically strong automation engineer with deep experience designing control systems from the ground up and supporting complex integrated automation environments.

🔧 Key Responsibilities

Control System Design & Engineering

  • Design complete control systems from concept through implementation

  • Develop electrical/control system architectures including:

    • Hardware

    • Software

    • Networks

    • Instrumentation

  • Perform electrical panel design and power calculations

  • Select and configure control system components

  • Optimize hardware layouts and panel locations for system efficiency

PLC/DCS Programming

  • Design, develop, and implement PLC/DCS control logic

  • Program using:

    • Ladder Logic (required)

    • Structured Text (required)

    • C++ (preferred)

    • Visual Basic (preferred)

  • Develop software design documentation and operational descriptions

  • Implement efficient, maintainable, and scalable control code

  • Perform scan time analysis, processor loading calculations, and network timing analysis

Safety & Risk Analysis

  • Support hazard analysis development and mitigation

  • Design safety-critical and redundant control systems

  • Implement SIL/PL-rated safety systems where applicable

  • Ensure compliance with client standards and regulatory codes

System Integration & Commissioning

  • Support system integration with multidisciplinary project teams

  • Assist with startup, troubleshooting, and commissioning activities

  • Diagnose and resolve control system issues during installation and testing

  • Develop smart diagnostics and fault mitigation logic

Documentation & Technical Leadership

  • Develop detailed technical documentation including:

    • Schematics

    • Network layouts

    • Acceptance test plans

    • Maintenance plans

    • Descriptions of operation

  • Act as technical lead on projects

  • Mentor junior engineers, technicians, and contractors

✅ Required Qualifications

  • Bachelor’s degree in Electrical Engineering required

    • Other engineering disciplines may be considered if directly related to controls/electrical engineering

  • 5+ years of controls engineering experience covering:

    • PLC programming

    • Electrical design

    • Industrial automation

    • System integration

  • Strong experience with:

    • Allen-Bradley and/or Siemens platforms

    • Ethernet-based remote I/O systems

    • AutoCAD

    • Distributed control systems

⭐ Preferred Experience

  • ASTM standards

  • Attractions or ride systems engineering

  • Safety engineering

  • Instrumentation systems

  • Complex motion control systems

  • Entertainment or manufacturing automation environments

🛠️ Technical Skills

✔ Controls Engineering
✔ PLC Programming
✔ Electrical Design
✔ Industrial Automation
✔ System Integration
✔ AutoCAD
✔ Ladder Logic
✔ Structured Text
✔ Allen-Bradley
✔ Siemens
✔ Ethernet/IP Networks
✔ Risk Assessment
✔ Commissioning & Startup Support

🎯 Ideal Candidate

  • Strong hands-on controls engineer capable of designing systems from scratch

  • Experienced in large-scale automation projects and complex integrated systems

  • Comfortable working in multidisciplinary engineering environments

  • Skilled at troubleshooting, commissioning, and optimizing industrial control systems

  • Strong communicator with technical leadership capabilities

  • Able to thrive in fast-paced industrial and construction environments

📋 Additional Details

  • Up to 30% travel required (typically closer to 10%)

  • Must be able to support off-shift commissioning activities as needed

  • Position involves work in:

    • Office environments

    • Industrial facilities

    • Construction sites

  • Physical requirements include lifting, climbing, equipment access, and extended computer usage

🌟 Why Join

  • Work on cutting-edge automation and systems integration projects

  • Exposure to large-scale industrial and entertainment automation systems

  • Opportunity to lead technically complex engineering initiatives

  • Collaborative engineering environment with growth potential

  • High-impact role supporting advanced automation technologies

 

Electrical Controls Engineer - Dekalb, IL - $60,000 - $80,000

Electrical Controls Engineer

Dekalb, IL

$60,000 - $80,000

 

Job Description

From a small family business to a multi-billion dollar global company, Sonoco has been changing the face of products and packaging since 1899 — all while keeping the heart of “People Build Businesses” alive.

 

Our talented people are at the core of our growth, constantly reinventing the Sonoco wheel with brilliant solutions every year. Today we are a world leader in global packaging solutions with diversified operations in over 34 countries. We're extremely proud of our portfolio of brands, our achievements in sustainability and industrialization and the groundbreaking work accomplished by our people.

 

This position reports directly with Machinery Manufacturing Manager, the following job description outlines the essential functions of designing electrical control systems for heat seal packaging machinery from start to finish.  The following lists are not exhaustive, and the engineer is expected to assume any and all duties assigned by management irrespective of whether such duties are specifically included in the following.

 

What you’ll be doing:

·        Ability to design and develop machine controls for heat seal packaging machinery

·        Design electrical schematics using AutoCAD Software or equivalent

·        Ability to develop electrical enclosure panel layouts using AutoCAD or equivalent computer software

·        Develop machine controls Bill of Materials using Syteline ERP system

·        Testing and debug of electrical control circuits

·        Ability to integrate various inkjet, laser, or robotic systems

·        Programming of machine control components consisting of A-B PLC’s, HMI’s and others

·        Ability to manage multiple projects

·        Assist in machine manual development & quoting needs

·        Experience programming other types of PLC’s (ex. Omron) and HMI’s is a plus

·        Work and communicate effectively with other groups within engineering and assembly departments

·        Perform final machinery check-offs to verify all systems functionality

·        Help customer support thru phone support to answer technical questions, support during machinery factory acceptance visits, and other issues

·        Provide technical assistance to machine assembly and sales as required

·        Communicate effectively to department manager regarding project progress, achieving goals, and customer expectations

·        This position is located in DeKalb, IL

 

We’d love to hear from you if:

·        Education: B.S. in Electrical Engineering or equivalent work experience

·        Ability to work with minimum supervision

·        Familiarity with electronic test instrumentation

·        Ability to read/write and follow verbal and written instructions

·        Proficient in Allen Bradley PLC and HMI programming a must

·        Experience designing, testing, and troubleshooting of industrial equipment with electro-mechanical components; example: relays, motor starters, temperature controllers, and others

·        Proficient using AutoCAD software or equivalent for electrical designing

·        Basic computer experience with file processing, email, Web navigation, and MS office

·        Ability to adapt to new machine controls software’s and updating as needed

·        Healthy attitude to work within a team environment

·        One year (Experience through co-ops and/or internships is acceptable)

 

Compensation:

·        The annual base salary range for this role is from $60,675.00 to $72,810.00

·        An annual bonus is awarded to eligible employees upon attaining various business and individual goals as defined by the Company and the department leader.  This annual bonus is discretionary, and the Company has sole discretion to determine the amount of the award.

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