Senior DeltaV Controls Engineer

📍 Location: Raleigh, NC (Onsite)
💼 Employment Type: Full-time | Mid-Senior Level
💵 Compensation: $141,000 – $170,000 (based on experience)
🛂 Visa Sponsorship: Not available
🚚 Relocation Assistance: Not available
👤 Openings: 1

About the Role

We are seeking a Senior DeltaV Controls Engineer to lead the design, implementation, and management of large-scale automation projects within the Life Sciences industry. This position requires deep technical expertise in Emerson DeltaV systems, strong knowledge of cGMP-compliant solutions, and the ability to deliver projects through their full lifecycle.

The ideal candidate will be a hands-on technical leader with extensive experience in automation, industrial networking, and regulatory compliance, while also mentoring junior engineers and collaborating with cross-functional teams.

Key Responsibilities

Lead the design and implementation of DeltaV control systems for complex Life Sciences projects.
Develop and manage project schedules, budgets, and resources to ensure on-time, on-budget delivery.
Design batch sequencing, phase logic, and recipe structures to optimize efficiency and compliance.
Develop DeltaV graphics using DeltaV Live and DeltaV Operate in alignment with ISA-101 guidelines.
Drive standardization with a class-based design approach across projects.
Specify, procure, and integrate instrumentation, hardware, and industrial networking solutions (Ethernet/IP, Modbus TCP/IP, Profibus, Foundation Fieldbus, OPC UA).
Define and plan DeltaV licensing requirements for cost-effective, scalable system deployment.
Ensure compliance with GAMP5, cGMP, and 21 CFR Part 11 regulatory standards.
Manage Factory Acceptance Testing (FAT) and Site Acceptance Testing (SAT).
Provide technical leadership and mentorship to junior engineers and teams.
Collaborate with stakeholders, regulatory bodies, and clients to ensure project success.
Troubleshoot complex automation issues and implement continuous improvements.
Travel up to 25% for commissioning and on-site client engagement.

Qualifications

Bachelor’s degree in Electrical Engineering, Control Systems, Chemical Engineering, or related field.
8–15 years of automation and control systems engineering experience, specifically in Life Sciences.
Extensive hands-on experience with Emerson DeltaV systems (DeltaV Live, DeltaV Operate).
Expertise in ISA-101 HMI design principles and ISA-88 batch processing.
Strong knowledge of industrial networking protocols (HART, Foundation Fieldbus, Profibus, Modbus, Ethernet/IP, OPC UA, IO-Link).
Experience with cGMP, GAMP5, and regulatory compliance for Life Sciences manufacturing.
Familiarity with Rockwell Automation, Siemens PCS7, Ignition, or other DCS/SCADA systems (plus).
Strong leadership and communication skills, with experience leading multi-disciplinary teams.

Why Join

Work on mission-critical Life Sciences automation projects that directly impact biopharmaceutical and medical device manufacturing.
Opportunity to lead full project lifecycles with ownership and accountability.
Be part of a collaborative, expert-driven team with continuous professional growth and development.

Key Skills

⚙️ 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.

Senior DeltaV Controls Engineer | Life Sciences Automation | Raleigh, NC | $141K–$170K

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

Your new job awaits.