Electrical Safety

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.

 

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

Senior Electrical & Controls Engineer

📍 Location: Multiple U.S. Locations (must be near a manufacturing site)
🏠 Work Model: Hybrid (flexibility when not traveling)
💼 Employment Type: Full-Time
🎓 Education: Bachelor’s Degree in Electrical Engineering required
📈 Experience Level: Mid-Senior
🕒 Experience Required: 5–7+ years
✈️ Travel: 50–75% (North America)
🌎 Visa Sponsorship: Not available
🚚 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 ($1M–$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

  • Bachelor’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 ($500K–$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 (50–75%)

Screening Questions

  • Do you hold a Bachelor’s degree in Electrical Engineering?

  • Do you have project engineering or project management experience?

  • Are you open to travel (40–60%+)?

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

 

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