Smart Manufacturing

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

 

Digital Manufacturing Engineer – MES & Industrial Automation | Wisconsin

Digital Manufacturing Engineer – MES

📍 Location: Waukesha, Wisconsin
🏢 Work Model: Primarily Onsite (Flexible for appointments, weather events, etc.)
💼 Employment Type: Full-Time
💰 Base Salary: $105,000 – $120,000
🎯 Bonus Eligible: Yes
✈️ Travel: Occasional
🎓 Education: Bachelor’s Degree Required

Role Overview

We are seeking a Digital Manufacturing Engineer (MES) to join a corporate Advanced Manufacturing team driving digital transformation across multiple manufacturing sites.

This role focuses on building and integrating shop-floor digital solutions that enable manufacturing teams to operate more efficiently, accurately, and intelligently. You will solve complex operational challenges using MES, analytics, and enterprise integration — while leading projects and mentoring others.

This is a hands-on, high-impact engineering role at the center of a broader digitalization strategy.

What You’ll Be Doing

🔹 MES & Shop-Floor Application Development

  • Build and deploy Tulip applications with MES as a primary focus

  • Integrate MES platforms with enterprise systems such as:

    • SAP

    • CMMS

    • Other operational platforms

  • Support troubleshooting and continuous improvement of deployed MES systems

🔹 Data & Analytics

  • Design and maintain dashboards using:

    • Power BI

    • Tulip Analytics

  • Ensure accuracy and integrity of manufacturing data

  • Develop cloud-based reporting and analytics solutions

🔹 OT & Enterprise Integration

  • Integrate OT systems with enterprise platforms using:

    • REST APIs

    • OPC

    • MQTT

  • Work with PLCs, SCADA, QMS, and data historians

  • Support lab testing and onsite proof-of-concept initiatives

🔹 Continuous Improvement & Support

  • Support end-of-line test cell enhancements

  • Participate in an on-call rotation for after-hours support

  • Lead training and knowledge transfer sessions for operations teams

  • Manage project schedules, budgets, and scope changes

Required Qualifications

  • Bachelor’s degree in:

    • Engineering

    • Industrial Technology

    • Business (with relevant experience)

  • 5+ years of progressive experience supporting manufacturing technology

  • Hands-on experience designing or supporting shop-floor software solutions

  • Experience working with MES platforms

Preferred Qualifications

  • Experience managing technical projects (requirements, budgets, timelines)

  • Strong understanding of manufacturing systems including:

    • MES

    • QMS

    • PLCs

    • SCADA

    • Data Historians

    • CMMS

  • Programming experience in:

    • Python

    • JavaScript

    • C#

  • Strong SQL experience (complex queries, stored procedures, triggers)

  • Experience with OPC servers and industrial data tags

  • Experience integrating OT systems with enterprise platforms

  • Cloud-based analytics/reporting experience

  • Ability to lead workshops and gather complex manufacturing requirements

Ideal Candidate Profile

  • Strong understanding of how digital tools improve shop-floor performance

  • Experience diagnosing and resolving MES errors

  • Comfortable handling multiple change requests

  • Able to translate machine limitations, bottlenecks, and VOC into technical solutions

  • Practical, solutions-oriented mindset

  • Capable of balancing hands-on development with strategic project leadership

Why This Role Stands Out

  • High-visibility digital transformation initiatives

  • Modern, state-of-the-art manufacturing facility

  • Collaborative Advanced Manufacturing team

  • Flexibility when needed (appointments, weather events, etc.)

  • Bonus eligibility and strong benefits package

  • Strong culture focused on innovation and operational excellence

Benefits Overview

  • Medical, Dental, Vision

  • 401(k)

  • Bonus eligibility

  • Modern facility amenities

  • Employee engagement programs

  • Product discount programs

 

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