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.

Windows Software Engineer – Canonsburg, PA - $118,000 -$135,000 - SECRET CLEARANCE - Relocation available

Windows Software Engineer – Canonsburg, PA
$118,000 -$135,000
Relocation available

Basic Qualifications

Requires a Bachelor’s degree in Computer Science, or a related Science, Engineering or Mathematics field. Also requires 5+ years of job-related experience, or a Master's degree plus 3 years of job-related experience.

CLEARANCE REQUIREMENTS:

Department of Defense Secret security clearance is preferred at time of hire, but must be obtainable within a reasonable period of time as determined by program requirements. Applicants selected may be subject to a U.S. Government security investigation and must meet eligibility requirements for access to classified information. Due to the nature of work performed within our facilities, U.S. citizenship is required.

Responsibilities for this Position

General Dynamics Mission Systems is currently seeking a Windows Software Engineer (Advanced Software Engineer) in our Canonburg, PA facility.

Progeny Systems, a business area within the General Dynamics Mission Systems company, is a high-tech business focusing on software and hardware system integration, cutting-edge research and development, and manufacturing. We deliver architectures, designs, testing, and production of the current and next generation torpedo guidance and control systems for the Department of Defense providing the warfighter with advanced capabilities in target detection, acquisition, and prosecution. We are a technology leader in numerous areas including technology insertion; acoustic sensors; signal processing; guidance; cyber secure; and high reliability systems.

Duties and Tasks:

• This position will involve the design, development, testing, integration and configuration of software applications and components as well as engineering expertise in diagnostics/debugging issues in existing code.

• You will collaborate across the functional teams to resolve issues and recommend solutions to ensure that your Software and the system meets requirements with the performance needed for deployment. Strong problem-solving and communication skills

• In addition, this position will require the documentation of software development including development of test plans, design documentation, and maintaining design requirements.

Knowledge, Skills and Abilities:

• Proficiency with one/more of the following:

• C/C++

• Object Oriented Development.

• National Instruments Lab Windows/CVI software/MATLAB/Coder/Compiler/MEX

• Windows/Visual Studio

• SQL/SQL Server or like relational database experience.

• Comfortable in implementing ideas from scratch, owning major application features, and take responsibility for their maintenance and improvement over time.

• Experience participating in technical architecture decisions for complex products.

• A significant level of Windows application development architecture expertise (e.g., Win32 apps, WPF apps, WinUI 3 apps).

• Deep understanding of software design patterns such as MVVM, MVP, etc.

• Experience with Windows kernel level debugging and diagnostics using tools such as Windows DDK or WinDBG or equivalent.

• Demonstrated in-depth experience developing, testing and debugging software for Windows OS using Visual Studio IDE and Windows SDK.

• Demonstrated in-depth understand of Windows Low Level Systems development and API.

• Compiling and assessing user feedback to improve software performance.

• Experience with DevOps concepts such as:

• Implementing Version Control and standing up branching strategies.

• Automating processes for build, test, and deploy.

• Applied experience with agile/lean principles in software development.

Preferred Qualifications:

• Proficiency with utilizing basic lab equipment like Oscilloscopes, DMMs, Spectrum Analyzers, and other test equipment

• Proficiency with different communication protocols like GPIB, RS232, SPI, etc

• Experience with interfacing and integrating hardware devices, control, sim/stim, data acquisition, specifically with National Instruments Hardware like PXI, CRIO, CDAQ, etc.

Our Commitment to You:

• An exciting career path with opportunities for continuous learning and development

• Research oriented work, alongside award winning teams developing practical solutions for our nation's security

• Flexible schedules with every other Friday off work, if desired (9/80 schedule)

• Competitive benefits, including 401k matching, flex time off, paid parental leave, healthcare benefits, health & wellness programs, employee resource and social groups, and more.

• See more at gcom/careers/why-work-for-us/benefits

Workplace Options:

• This position is ON-SITE in Canonsburg, PA (relocation package/assistance may be available)

• A Hybrid work schedule may be available but will require a minimum of 3 day's per week on-site.