Controls Project Engineer

Aegis Worldwide; Milwaukee (WI); On-site; USD 120,000 - 140,000; Full time

Job summary

Aegis Worldwide is seeking a Controls Project Engineer for a growing automation company. You will own the controls portion from concept through commissioning, work with PLCs, HMIs, servos, robotics, and vision systems, and lead controls activities on large projects.

The role offers cradle-to-grave ownership across design, programming, debugging, startup, and customer commissioning, with 5–20% travel within the U.S. and some international trips.

Qualifications

• 5+ years in custom automation, machine controls, OEM, or systems integration.
• Strong experience with Allen-Bradley PLC/HMI programming from scratch.
• Deep understanding of PLCs/HMIs, servo/motion, VFDs, sensors, and safety systems.
• Ownership of projects and coordination of engineering resources.
• Excellent communication with technical teams and customers.

Responsibilities

• Design control systems and develop electrical schematics.
• Specify controls hardware, components, and architecture.
• Program Allen-Bradley PLCs and HMIs from scratch.
• Troubleshoot and debug automated machine sequences.
• Lead controls startup and customer commissioning.
• Coordinate controls engineering on larger projects.
• Review work and provide technical direction to peers.
• Communicate technical issues clearly to customers.

Skills

Custom automation

Machine controls

OEM integration

Systems integration

Allen-Bradley PLC/HMI programming

Troubleshooting

Technical ownership

Team coordination

Education

Bachelor's degree in Electrical Engineering or related field

Tools

AutoCAD

Fanuc integration

Yaskawa/Motoman interfacing

ABB

KUKA

Job description

Confidential Opportunity | Growing Automation Company

A well-established, highly technical automation company is expanding its engineering team and is looking for a Controls Project Engineer to take ownership of the controls side of custom automation projects from initial concept through programming, debug, startup, and customer commissioning.

This is a great opportunity for a controls engineer who wants to work on complete, highly automated systems rather than being limited to PLC programming, electrical design, or process controls. You’ll have the opportunity to work with robotics, vision, servo motion, HMIs, machine safety, pneumatics, and other advanced automation technologies while working alongside a strong engineering team.

Why This Opportunity Stands Out

• $120K–$130K base salary, with flexibility up to $140K for exceptional candidates
• Additional profit-sharing bonus that has consistently paid out several thousand dollars annually
• Direct-hire opportunity with a highly established automation company
• Work on custom automation systems for major household-name manufacturers
• True cradle-to-grave ownership — from controls design and programming through debug, startup, and customer commissioning
• Work with PLCs, HMIs, servos, robotics, vision systems, VFDs, pneumatics, safety systems, and industrial networks
• Opportunity to technically lead controls work on larger projects and coordinate other engineers/resources
• Close-knit engineering environment with strong employee tenure, including many employees with 20+ years at the company
• Stable organization with a long history of avoiding layoffs during slower business cycles
• Work for a growing automation company involved in the development of increasingly autonomous manufacturing facilities
• Opportunity to work on highly technical projects where you can see a system go from a clean-sheet concept to a fully functioning production line
• Approximately 5–20% travel, primarily within the U.S., with occasional trips to Mexico and Canada

What You'll Be Doing

The Controls Project Engineer will take technical ownership of the controls portion of custom automation projects, working closely with Mechanical Engineering, Assembly, customers, and other engineering resources.

Responsibilities will include:

• Design control systems and develop electrical schematics
• Specify controls hardware, components, and system architecture
• Program Allen-Bradley PLCs and HMIs from scratch
• Develop and troubleshoot automated machine sequences
• Configure and troubleshoot servos, VFDs, sensors, safety systems, and industrial networks
• Work hands-on during machine build and debug
• Troubleshoot issues across the entire machine, including controls, electrical, mechanical, pneumatic, and hardware-related problems
• Tune motion systems, adjust sensors, troubleshoot pneumatics, and validate machine safety systems
• Lead controls startup and customer commissioning
• Coordinate controls engineering activities on larger projects
• Review the work of other engineers and provide technical direction when needed
• Communicate directly with customers and explain technical issues in a way that is easy to understand
• Help identify and resolve project risks and technical challenges throughout the build

Ideal Background

We're looking for someone who understands the entire automated machine, not simply someone who programs PLCs or designs electrical systems in isolation.

Required:

• 5+ years of experience in custom automation, machine controls, OEM, or systems integration
• Strong experience with Allen-Bradley PLC/HMI programming from scratch
• Strong understanding of:
• PLCs/HMIs
• Servo/motion systems
• VFDs
• Sensors
• Machine safety
• Ability to troubleshoot the complete machine across electrical, controls, mechanical, pneumatic, and hardware issues
• Experience taking technical ownership of projects and coordinating engineering resources
• Strong communication skills with both technical teams and customers

Preferred:

• High-speed assembly or custom automated equipment experience
• Robotics, vision, dispensing, or advanced servo-motion experience
• Electrical controls design, including schematics, panel layouts, I/O, and component sizing
• AutoCAD experience
• Experience interfacing PLCs with Fanuc, Yaskawa/Motoman, ABB, KUKA, Cognex, or Keyence
• Siemens PLC/HMI or industrial robot programming
• Bachelor's degree in Electrical Engineering or related technical field

Who This Role Is Best For

This position is ideal for a technically curious controls engineer who likes figuring things out.

The best candidates will be engineers who don't want to spend their careers making minor PLC edits or working exclusively within one narrow area of controls. You'll have significant ownership over the systems you're building and will need to understand how the mechanical, electrical, pneumatic, hardware, and software pieces all work together.

You should also enjoy working directly with people. This role involves close collaboration with other engineers, manufacturing, leadership, and customers, so the ability to explain complex technical issues in straightforward terms is important.

Employment: Direct Hire

Compensation: $120K–$130K base, up to ~$140K for exceptional candidates

Bonus: Profit sharing; historically several thousand dollars annually

Travel: Approximately 5–20%, primarily U.S. with occasional Mexico/Canada travel

Schedule: Salaried / standard business hours

Start: ASAP