Senior Controls Systems Engineer – PLC, Robotics & Industrial Automation | Wisconsin

Senior Controls Systems Engineer

📍 Location: Waukesha, Wisconsin
🏢 Work Model: Primarily Onsite (flexible when needed for appointments, illness, or extreme weather)
💼 Employment Type: Full-Time
💰 Base Salary: $105,000 – $120,000
✈️ Travel: Occasional (primarily day trips to nearby facilities)
🎓 Education: Bachelor’s Degree in Engineering, Computer Science, or related field preferred

Role Overview

A leading advanced manufacturing organization is seeking a Senior Controls Systems Engineer to join its Advanced Manufacturing team.

This role focuses on designing, implementing, and scaling automation and controls systems across manufacturing operations. The engineer will develop PLC programs that interact with robotics, conveyors, machine vision, MES systems, and other automated equipment.

This position plays a critical role in improving automation capability, production quality, and operational efficiency across manufacturing sites.

Key Responsibilities

Automation & Controls Development

• Design and implement automated and semi-automated control systems

• Develop PLC code interacting with:

• Conveyors

• Industrial robots

• Manufacturing Execution Systems (MES)

• Machine vision systems

• Third-party equipment

• Build scalable and maintainable control architectures

Controls Engineering Leadership

• Act as a subject matter expert for plant control systems

• Mentor machine builders, automation vendors, and internal engineering teams

• Lead technical direction for automation projects

Industrial Automation Programming

• Architect, write, and debug PLC ladder logic and IPC software

• Develop well-structured, documented, reusable code

• Create intuitive HMI interfaces for complex manufacturing equipment

Manufacturing Automation Integration

• Integrate controls with:

• Robotics

• Machine vision

• Part tracking systems

• MES platforms

• Work with IT teams to connect manufacturing assets to enterprise networks

Machine Safety & Compliance

• Implement safety systems compliant with:

• ANSI

• RIA

• OSHA

• Design and program safety PLC systems protecting robotics and automated equipment

Capital Equipment Development

• Create RFQs/RFPs for automated equipment

• Lead equipment design reviews and technical evaluations

• Travel to supplier sites for:

• Equipment validation

• Factory acceptance testing

• Build event support

Legacy System Modernization

• Identify legacy control systems via risk assessment

• Develop remediation strategies

• Execute system upgrades and modernization initiatives

Required Qualifications

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

• 7+ years of experience with Rockwell Logix PLC platforms

• Strong experience developing controls for automated manufacturing systems

• Experience programming PLCs interacting with robotics, conveyors, and automated systems

• Strong troubleshooting and debugging capability

Preferred Experience

• Expert experience with:

• Rockwell Logix platforms

• GE RXi control systems

• Experience designing controls hardware and OT infrastructure

• Knowledge of industrial communication protocols

• Experience designing automated manufacturing equipment specifications

• Experience with:

• OPC servers

• Industrial historians

• SCADA platforms

• Industry 4.0 manufacturing systems

• Experience integrating IoT platforms with factory equipment

• Experience with SQL, Python, or Java

• Familiarity with ERP platforms such as SAP

• Experience with Fanuc robotics

Ideal Candidate Profile

The ideal candidate is a hands-on automation expert who:

• Has deep experience programming Rockwell / Allen-Bradley controls

• Has led automation implementations in high-volume manufacturing

• Can integrate robotics, MES, vision systems, and automated equipment

• Is comfortable mentoring vendors and internal engineers

• Can troubleshoot complex manufacturing systems under real production conditions

• Has strong problem-solving, leadership, and technical communication skills

Key Skills

• PLC Programming (Rockwell Logix)

• Industrial Automation

• Robotics Integration

• Machine Safety Systems

• SCADA / Industry 4.0

• Industrial Networking

• MES Integration

• Controls Architecture

• HMI Development

• Automation Project Leadership

Benefits Overview

• Comprehensive health benefits (medical, dental, vision)

• Retirement savings plan (401k)

• Modern facility with onsite amenities

• Employee engagement programs and events

• Product discount programs

• Strong culture focused on innovation and teamwork

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.

Senior Controls Engineer | Industrial Automation | Albuquerque, NM | $121K - $130K

Job Title: Senior Controls Engineer

Location: Albuquerque, NM (On-site)
Experience Level: Mid-Senior
Education: Bachelor's Degree
Industry: Industrial Automation
Salary: $121,000 - $130,000
Relocation Assistance: No
Visa Sponsorship: Not available

Job Description

We have an opening for a Senior Controls Engineer in Albuquerque, NM. This role involves leading the delivery of automation systems for a diverse range of industries, including semiconductor, life sciences, food and beverage, and more. You will have the opportunity to lead a team, interact directly with clients, and guide the development and implementation of automation solutions using PLC, DCS, HMI, and SCADA platforms.

In this leadership role, you will oversee the full project lifecycle from requirements gathering and specification development to testing, commissioning, and qualification of automation systems. This is a key position within the organization, and success is measured by securing repeat business with both new and existing clients.

Key Responsibilities

• Deliver innovative automation solutions for industrial processes and machinery, either independently or leading a team.

• Develop control system architectures, select appropriate components, and create detailed schematic diagrams and system documentation.

• Program PLC, DCS, and RTU controllers, develop HMI/SCADA visualization, and build databases for historical data storage and display.

• Implement and commission control systems at client facilities.

• Work with industrial networking protocols (Ethernet/IP, Profinet, Modbus, etc.) to design and implement fiber, wired, and wireless systems.

• Lead project management activities, including developing project execution plans, schedules, task prioritization, budget tracking, and conflict resolution.

• Oversee daily operations of projects up to $1M and ensure project profitability.

• Provide technical leadership on design standards, mentoring junior engineers and technicians.

• Serve as the Project Manager for smaller projects, ensuring successful delivery within scope and budget.

Qualifications

• Education: Bachelor of Science in Electrical/Control Engineering, Mechanical Engineering, Chemical Engineering, or Computer Science.

• Experience:

• Minimum 10 years of experience in Controls Engineering.

• Expertise with Rockwell Automation, Siemens, and Modicon PLCs.

• Proficiency in HMI/SCADA systems, including ICONICS Genesis64, Wonderware ArchestrA, and GE CIMPLICITY.

• Familiarity with DCS platforms like Emerson DeltaV or similar.

• Experience with SQL, .NET, Power BI, Grafana, and APIs.

• Prior experience in industries such as Semiconductor fabrication, Life Sciences, Building Automation, Food and Beverage, and Oil & Gas.

• Experience designing electrical schematics and control panels under 480VAC, as well as AutoCAD usage is preferred.

• Leadership Experience:

• Experience leading engineering teams, providing control system solutions.

• Ability to mentor less experienced engineers and technicians.

• Field device troubleshooting and job estimating experience.

Physical Demands

• Visual acuity, color perception, hearing, clear speech, manual dexterity, driving, lifting, and the ability to mount/dismount equipment, pushing, and pulling.

Working Environment

• Standard office environment, on-site office, and industrial environments. Frequent use of personal computers, fax/copy machines, and phones.

If you have a passion for delivering innovative automation solutions and have a diverse engineering skill set, we encourage you to apply for this leadership position.