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
Can you design and build a PLC system from scratch?
Do you have at least 5 years of Controls/Test Engineering experience?
Do you hold a Bachelor's Degree in Engineering?
Do you have experience with Rockwell software (RSLogix, Studio 5000, FactoryTalk)?
Do you have PLC and HMI programming experience?
Have you supported the design, development, installation, and troubleshooting of production equipment?
Do you have experience with Visual Studio, SQL, and Microsoft applications?
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.