Controls Engineer

Job Title:

Controls Engineer

Job Description

The Controls Engineer will oversee the design, development, execution, and delivery of new industrial control system projects while also maintaining and improving existing equipment at a growing manufacturing facility in Beaver Dam, WI. This role focuses on automation controls systems design, PLC and HMI programming, troubleshooting, and start-up commissioning. The Controls Engineer will also support the broader engineering team by providing technical expertise, mentoring associates, and driving continuous improvement in processes and standards.

Responsibilities

* Problem solve equipment control issues and implement effective, sustainable improvements to enhance reliability and performance.

* Provide control system guidance for capital projects, collaborating with equipment suppliers and installation contractors to ensure proper design and integration.

* Serve as the subject matter expert for facility engineering resources on control systems programming and related automation technologies.

* Prepare comprehensive project deliverables, including statements of work, status reports, and budgets, ensuring projects stay on scope, on schedule, and within budget.

* Ensure adherence to established company standards, engineering methodologies, and best practices in all control system designs and implementations.

* Collaborate with internal customers, discussing technical needs in clear, non-technical language to ensure alignment and understanding.

* Analyze customer requests, clarify requirements, and document them in detailed Functional Specifications.

* Translate functional requirements into robust System Design Specifications that guide implementation and programming efforts.

* Develop and modify PLC, HMI, and related automation programs to meet system requirements and operational needs.

* Lead, mentor, and guide project team members to deliver on project and program requirements, fostering knowledge sharing and skills development.

* Ensure customer acceptance of control system changes by performing testing and validation, and by training users on new or modified business processes and system operations.

* Support start-up and commissioning activities for new or upgraded equipment, verifying proper operation of PLCs, HMIs, drives, and associated control hardware.

* Interpret and work from electrical schematics and documentation to troubleshoot and optimize control systems for equipment such as conveyors, rotors, and stators.

Essential Skills

* Minimum 3 years of experience programming industrial control systems, including PLCs and HMIs, and working with industrial communication protocols.

* Ability to troubleshoot PLCs with at least 3 years of hands-on experience diagnosing and resolving control system issues.

* Minimum 3 years of experience programming PLCs, HMIs, and drives using Rockwell RSLogix/Studio 5000 and Factory Talk View (FTV View).

* Proficiency in PLC programming and troubleshooting in an industrial automation environment.

* Experience with automation systems involving equipment such as conveyor systems, rotors, and stators.

* Ability to read, interpret, and work from electrical schematics to support design, troubleshooting, and commissioning activities.

* Experience with Rockwell automation platforms, including Studio 5000 and Factory Talk software suites.

* Demonstrated skill in start-up commissioning of control systems, including testing, validation, and tuning.

* Strong communication skills, with the ability to explain technical concepts in non-technical language to internal customers.

* Ability to translate customer needs into Functional Specifications and System Design Specifications.

* Capability to mentor and guide team members in control systems and automation best practices.

Additional

Skills & Qualifications

* Experience working with conveyor systems and related material handling equipment.

* Familiarity with control systems for rotors and stators in industrial applications.

* Exposure to or experience as a subject matter expert in Rockwell-based automation environments.

* Background in developing or improving standards and methodologies for control system design and implementation.

* Experience using tools or methods for flow analysis or process flow optimization in an automated environment.

* Prior involvement in capital projects, including coordination with equipment suppliers and installation contractors.

* Experience training end users and operations personnel on new or modified control systems and business processes.

* Interest in career growth within a rapidly expanding facility and willingness to take on increasing responsibility over time.

Work Environment

This position is fully onsite in a plant environment in Beaver Dam, WI, where the Controls Engineer will work hands-on with production equipment and control systems most of the time. The facility is a brand-new, modern site in a high-growth phase, providing opportunities to shape standards, processes, and future…