⚙️ 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.