Sr, Controls Systems Engineer

Senior Controls Systems EngineerWaukesha, WI We are seeking a Senior Controls Systems Engineer to lead the design, implementation, and scaling of automated and semi-automated manufacturing systems supporting high-volume production environments. This role serves as a technical leader and subject matter expert, driving controls architecture, automation integration, and modernization initiatives across manufacturing operations. If you enjoy solving complex automation challenges and influencing plant-wide engineering standards, this is an excellent opportunity to make a direct impact. Key Responsibilities Design, program, and implement PLC-based control systems for automated manufacturing equipment Develop structured, reusable PLC code interacting with: Conveyors Robotics systems Manufacturing Execution Systems (MES) Machine vision and third-party equipment Establish factory and machine-level controls standards for internal teams and external equipment suppliers Lead controls integration efforts for new automation and equipment upgrades Perform risk assessments on legacy controls systems and execute modernization plans Design and implement ANSI / RIA / OSHA compliant machine safety systems Develop intuitive HMI interfaces for complex machinery troubleshooting Collaborate with IT teams to connect manufacturing equipment to enterprise networks Support RFQ/RFP development and participate in supplier design reviews Travel to supplier locations for equipment qualification, FAT/SAT, and build support Provide mentorship and technical guidance to engineering teams and automation partners Required Qualifications Bachelor's degree in Engineering, Computer Science, or related technical discipline 7+ years of PLC programming experience using Rockwell / Allen-Bradley Logix platforms Experience supporting automated manufacturing or assembly environments Strong background integrating automation systems and production equipment Ability to travel periodically to support equipment builds and plant operations (primarily day trips) Preferred Qualifications Expert-level experience with automated controls integration in high-volume discrete manufacturing Controls hardware and OT infrastructure design experience Industrial communication protocols knowledge Machine safety circuit design and Safety PLC programming Experience with SCADA, OPC servers, or manufacturing data historians Robotics integration experience (Fanuc preferred) MES or IoT manufacturing integration experience SQL, Python, or Java exposure a plus SAP or ERP system experience What You'll Bring Strong analytical and problem-solving skills Ability to lead cross-functional automation projects Ownership mindset with strong decision-making capability Passion for continuous improvement and engineering excellence Ability to mentor and influence teams across manufacturing operations

Created: 2026-03-04