Senior Controls Engineer

We believe power is a promise – a shared commitment to be there for others when it matters most. Generac is seeking a Senior Controls Engineer to join our Advanced Manufacturing team at our Corporate HQ in Waukesha, WI.

• Develop new and/or improved processes through the application of theoretical and practical engineering.
• Design and build factory‑level and line/machine‑level controls standards and specifications for application by internal equipment development team and external partners.
• Act as the corporate SME for plant resources on control systems programming by architecting, writing and debugging PLC ladder logic/IPC software; generate code that is organized, structured, documented, maintainable and reusable.
• PLC code interacts with subsystems such as conveyors, robots, 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 RFQ/RFPs, organize cross‑functional reviews of machine requirements, design, qualification and capability, and engage machine suppliers for automated equipment design reviews and proposals.
• Travel to machine suppliers for equipment qualification, acceptance testing and support during build events.
• Frequent travel to other Generac sites for support as needed (generally day trips).

• Bachelor of Science Degree in Engineering, Computer Science, or related discipline.
• 7+ years of experience with Rockwell Logix.

• 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 designing controls hardware and OT infrastructures, including a thorough understanding of industrial communication protocols.
• Experience 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.
• Able to communicate effectively in a worldwide environment.
• Previous experience with SAP or equivalent ERP.
• Experience with Fanuc robotics a plus.

Works independently, with occasional guidance on challenging technical issues; requires in-depth knowledge and/or breadth of expertise; uses best practices and knowledge of internal and external business issues to improve products or services; recommends solutions and best practices; strong conceptualization, visualization, and creativity; strong time management, prioritization and analytical problem solving; solves complex problems; takes a new perspective using existing solutions; strong decision‑making skills;

may lead cross‑functional project teams; ensures success cross‑functionally; actively coaches colleagues with less experience; offers recommendations and implements solutions; takes ownership of designs; participates in standards and procedure development; leads efforts to improve the financial impact of engineering activities and has a thorough understanding of how other functions impact the business.

While performing the duties of this job, the employee is regularly required to talk and hear and use hands to manipulate objects or controls; is regularly required to stand and walk. On occasion the incumbent may be required to stoop, bend or reach above the shoulders. The employee…