Sr. Controls Systems Engineer

Sr. Controls Systems Engineer

Location:

Waukesha, Wisconsin

Salary: $105,000 to $120,000

Industry: Engineering

Job Category:
Manufacturing - Automation

• Experience with control panel design, electrical with automated machines (field wiring, control wiring, installation)
• Experience installing or writing programs to accommodate fixturing or tool and die machines and tooling (new product introduction/PIPO)
• Programming experience – C++, Visual Basic, G Code (tool and die), SEAScape, PLC, Rockwell, Allen Bradley, GE Emerson, Serbo drives, variable frequency drives, Atlas Copco for tooling
• Experience implementing automation with the controls

• In this role you will be responsible for design, implementation and successfully scaling automated and semi‑automated control systems utilizing sound engineering principles and technologies.
• Develop PLC code that will interact with subsystems such as conveyors, robots, Manufacturing Execution System (MES), machine vision, and 3rd party equipment.
• Perform research and development on new technologies necessary to tackle complex assembly and automation problems that have a direct impact on the quality and delivery of products.
• Identify legacy controls by risk assessment, create remediation plan, and execute controls upgrade according to plan.
• Use your leadership skills for direction and mentorship of machine/automation suppliers; be the driver on internal projects; serve as a technical resource to other engineering groups and project leaders, while driving standards and process improvements.

• Develop new and/or improved processes through the application of theoretical and practical engineering.
• Design and build out factory level, and line/machine level controls standards and specifications for application by internal equipment development team and external partners.
• Acts as the corporate SME for plant resources on control systems programming by architecting, writing and debugging PLC ladder logic/IPC SW with an emphasis on generating code that is organized, structured, documented, maintainable and reusable. PLC code will interact with subsystems such as conveyors, robots, Manufacturing Execution System (MES), machine vision, part tracking systems, and 3rd party equipment.
• Implement (ANSI/RIA
  15.06/OSHA compliant) control reliable safety systems for safeguarding robots, gantries, conveyors, and other high‑volume manufacturing equipment.
• Generate aesthetically simple HMI screens for complex machinery while providing sufficient feedback for troubleshooting.
• Work with IT to connect manufacturing assets to enterprise network using established standards/guidelines.
• Keep abreast of all meaningful technical trends and developments and incorporate them in appropriate assignments.
• Create request for quotation/proposal (RFQ/RFPs), organize cross‑functional reviews of the machine requirements, design, qualification and capability and engage machine suppliers for automated equipment design reviews and proposals.
• Travel to the machine suppliers for equipment qualification, acceptance testing and support during build events.

• Bachelor of Science Degree in Engineering, Computer Science, or related discipline.
• Note:
  
  we are also open to candidates with a Sr. Controls Engineering Specialist background if they lack an engineering bachelor’s but possess extensive experience.
• 7+ years of experience with Rockwell Logix.
• Frequent travel to other sites for support as needed (generally day trips).

• Expert‑level experience in design, program, integration, and validation of controls in high‑volume automated process equipment for discrete manufacturing using Rockwell Logix and GE RXi platforms.
• Experience in designing controls hardware and OT infrastructures including a thorough understanding of industrial communication protocols.
• Experience in creating technical specifications for automated manufacturing equipment, machine qualification requirements, design of experiments and failure analysis.
• Expertise in the design of machine safety circuits and programming of safety PLCs.
• Expertise with software and SCADA platforms to support Industry 4.0 manufacturing projects, including historians and OPC servers.
• Experience with machine integration with common IoT platforms.
• Experience with SQL and Python/Java would be a plus.
• Ability to communicate effectively in a worldwide environment.
• Previous experience with SAP or equivalent ERP.
• Experience with Fanuc robotics a plus.

• MS Word Resume
• Required compensation
• Contact information
• Availability

Upon receipt, one of our managers will contact you to discuss the position in full detail.

Stephen Fleischner
INTERMEDIA GROUP, INC.
Email: sf
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