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 Controls Engineer | Automation & PLC Programming | Waukesha, WI | $96K–$130K + Bonus

⚙️ Senior Controls Engineer

📍 Waukesha, WI | Onsite (with office space available)
📅 Full-time | Mid-Senior Level | Engineering – Electrical

💰 Salary: $96,900 – $130,000 + Bonus Eligible
✨ Benefits: Full benefits package (Medical, Dental, Vision, Life, Retirement, PTO)
🚗 Travel: Occasional (including day trips to supplier or other U.S. sites)

🚀 About the Role

We are seeking an experienced Senior Controls Engineer to join our Advanced Manufacturing team. In this role, you’ll be responsible for designing, implementing, and scaling automated and semi-automated control systems that power high-volume manufacturing environments.

You’ll lead the development of PLC code to integrate subsystems like conveyors, robots, machine vision, MES, and third-party equipment. This role is perfect for a hands-on engineer with a passion for automation, Industry 4.0, and driving innovation in manufacturing.

🛠️ Key Responsibilities

• Design and develop new or improved processes applying advanced engineering principles.

• Build and maintain factory-level and machine-level control standards for internal teams and external partners.

• Act as the subject matter expert for controls programming, writing/debugging PLC ladder logic and IPC software with organized, maintainable, and reusable code.

• Implement ANSI/RIA/OSHA-compliant control-reliable safety systems for robots, gantries, and conveyors.

• Design user-friendly HMI screens for complex machinery.

• Partner with IT to connect manufacturing assets to enterprise networks.

• Lead supplier engagements: create RFQs, participate in design reviews, and oversee machine acceptance testing.

• Travel to supplier sites for equipment qualification and support build events.

• Support legacy controls remediation through risk assessment and upgrades.

• Mentor teams, drive process improvements, and act as a technical resource across engineering.

🎯 Required Qualifications

• Bachelor’s degree in Engineering, Computer Science, or related discipline.

• 7+ years of experience with Rockwell Logix.

✅ Preferred Qualifications

• Expertise designing, programming, and validating controls in high-volume automated manufacturing (Rockwell Logix, GE RXi).

• Strong knowledge of Industrial Communication Protocols and controls hardware/OT infrastructure.

• Hands-on experience with machine safety circuits, safety PLCs, and automation systems.

• Exposure to SCADA, Industry 4.0 platforms, OPC servers, and Historians.

• SQL and scripting knowledge (Python/Java a plus).

• Familiarity with Fanuc robotics and ERP systems (SAP preferred).

• Strong communication skills in global/technical environments.

💡 Skills & Attributes

• Works independently while providing mentorship to less experienced engineers.

• Strong conceptualization, visualization, and problem-solving skills.

• Ability to manage multiple projects, prioritize effectively, and deliver results.

• Experience improving financial and operational performance through engineering activities.

• Collaborative leader who can influence cross-functional teams.

📌 Interview Process

• Recruiter screen

• Hiring manager interview

• Technical deep-dive interview

• Final onsite with cross-functional stakeholders

🏆 Why Apply?

This is a high-impact role where you’ll help shape the future of advanced manufacturing and automation. If you’re passionate about solving complex automation challenges, working with cutting-edge robotics and controls systems, and driving efficiency across production, this role offers the platform to make a real difference.