Controls Engineer; Rockwell, PLC, HMI

Controls Engineer (ROCKWELL, PLC, HMI)

Location: Waukesha, Wisconsin

Relocation Assistance Available

Base Salary: $97,000 to $143,000

Industry: Manufacturing & Production

Job Category: Engineering - Electrical

• The Controls Engineer is responsible for supporting plant leadership in achieving business and financial goals by developing and maintaining robust testing and assembly processes.
• The Controls Engineer will actively participate and support the design, development, fabrication, validation, installation, and troubleshooting of production equipment and programs.

• Provide guidelines for the design and selection of test equipment, developing testing protocols, test data collection programs and best practices.
• Support, service, and troubleshoot controls for production equipment, test equipment, and electrical systems within the plant.
• Develop test equipment specifications ensuring compliance with electrical safe work practices and OSHA requirements. Identify and remediate potential safety hazards.
• Develop interfaces between SQL databases and production systems.
• Enforce safety expectations, document, and communicate hazards and unsafe conditions to ensure a zero-incident culture and product conformance to electrical safety and quality standards.
• Collaborate with manufacturing, MESH, manufacturing engineering, quality, product design engineering, suppliers, and customers as needed.
• Perform root cause and failure analysis, applying critical thinking and problem‑solving skills.
• Guide the capital equipment selection process and develop Capital Appropriation Requests (CARS) for new products or process initiatives.
• Actively participate in assessment processes within the manufacturing environment, potentially as a category lead or champion.
• Lead or co‑lead cost‑out initiatives and promote a culture of continuous improvement. Collaborate cross‑functionally using Lean and Six Sigma tools to solve manufacturing problems.
• Leverage advanced technology to improve the effectiveness of information systems for controls.
• Seek opportunities to eliminate waste associated with the flow of factory floor test information. Lead or co‑lead projects, develop goals, budgets, and work breakdown structures.
• Execute sustained change management within manufacturing operations, utilizing change management techniques such as ADKAR to drive and sustain improvements.

• Bachelor’s degree in Engineering from an accredited institution.
• Minimum of five (5) years of Controls/Test engineering experience.
• Able to design a PLC from scratch.
• Experience with Rockwell Software (RSLogix 5, RSLogix 500, RSLogix 5000, Studio 5000, Factory Talk View ME, Factory Talk SE).
• Experience with PLC and HMI programming, and an understanding of safety systems design.
• Experience with various programming software including Visual Basic/Studio, SQL, and other Microsoft applications.