Senior Controls Engineer - Automation & Manufacturing Systems
Job in
Waukesha, Waukesha County, Wisconsin, 53189, USA
Listed on 2026-03-03
Listing for:
Trispoke Managed Services Pvt Ltd
Full Time
position Listed on 2026-03-03
Job specializations:
-
Engineering
Systems Engineer, Automation Engineering, Electrical Engineering, Robotics
Job Description & How to Apply Below
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.
You'll 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/RIA
15.06/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.
- Bachelor's 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 (Ether Net/IP, Modbus, etc.).
- Experience designing and validating machine safety circuits and safety PLCs.
- Experience in automated manufacturing equipment qualification, DOE, and failure analysis.
- 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).
NetIP #Modbus #Safety
PLC #OTInfrastructure #Industry
40 #IoT #SQL #Python #Java #RFQ #RFP #Equipment Qualification #Control Systems #PLC #HMI #Factory Automation #Discrete Manufacturing #Engineering Leadership #Process Improvement #Automation Design #Manufacturing Excellence #System Integration
Position Requirements
10+ Years
work experience
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