Senior Controls Engineer – Automation & Manufacturing Systems

Waukesha, WI - USA

Monthly Salary: Not Disclosed

Posted on: 29-10-2025

Vacancies: 1 Vacancy

Job Summary

Job Title: Senior Controls Engineer Automation & Manufacturing Systems

Location: Onsite / Hybrid (Travel as required)

Employment Type: Full-Time / Contract

About the Role

In this role you will be responsible for the design implementation and scaling of automated and semi-automated control systems using advanced engineering principles and cutting-edge technologies. You will develop PLC code that integrates with subsystems such as conveyors robotics MES machine vision and third-party equipment to drive high-quality efficient manufacturing operations.

Youll also lead new technology development upgrade legacy control systems and provide technical mentorship to suppliers and internal engineering teams - all while ensuring compliance with ANSI/RIA15.06/OSHA safety standards.

Key Responsibilities

Design and implement factory-level and machine-level controls standards and specifications.
Develop and debug PLC ladder logic and IPC software (Rockwell Logix GE RXi) with well-documented maintainable and reusable code.
Integrate PLC systems with MES robotics conveyors and vision systems.
Design control-reliable safety systems for safeguarding high-volume manufacturing equipment.
Create intuitive HMI screens that simplify complex processes while providing rich diagnostic feedback.
Collaborate with IT to connect manufacturing assets to the enterprise network.
Research and develop innovative control system technologies to solve complex manufacturing challenges.
Write and manage RFQs/RFPs and lead cross-functional design reviews with equipment suppliers.
Support equipment qualification testing and build activities on-site and at supplier facilities.
Stay up to date with new technologies and industry trends to enhance automation processes.
Provide technical guidance and mentorship to internal and external engineering teams.

Minimum Qualifications

Bachelors degree in Engineering Computer Science or related discipline.
7 years of experience with Rockwell Logix platforms.
Strong background in manufacturing automation (not logistics).
Proven experience in controls programming hardware design and OT infrastructure.
Proficiency with Industrial Communication Protocols (EtherNet/IP Modbus etc.).
Experience designing and validating machine safety circuits and safety PLCs.
Experience in automated manufacturing equipment qualification DOE and failure analysis.

Preferred Qualifications

Expert-level experience in high-volume automated process equipment using Rockwell Logix and GE RXi.
Familiarity with SCADA platforms Historians OPC Servers and Industry 4.0 implementations.
Experience with IoT integration SQL and scripting languages (Python/Java preferred).
Exposure to Fanuc robotics SAP/ERP systems and machine vision.
Excellent problem-solving time management and analytical skills.
Strong leadership collaboration and communication abilities.
Ability to travel for supplier qualifications and on-site support (typically short trips).

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Job Title: Senior Controls Engineer Automation & Manufacturing Systems Location: Onsite / Hybrid (Travel as required) Employment Type: Full-Time / Contract About the Role In this role you will be responsible for the design implementation and scaling of automated and semi-automated control system...