Electrical Controls Engineer

Kids for the Future; City of Pewaukee (WI); On-site; USD 90,000 - 130,000; Full time

Job summary

Kids for the Future is seeking a skilled Controls Engineer to design, program, debug, and validate complex automation systems. You will work with PLCs, HMIs, robots, and motion controllers while coordinating with project teams to ensure on-time delivery and compliance with standards.

You will perform testing, deployment, FAT/SAT support, and thorough documentation. Occasional travel to customer sites will be required to support commissioning and post-installation activities.

Qualifications

• Bachelor’s degree in Electrical Engineering or related field or equivalent experience.
• At least 5 years in control systems work including PLC, HMI, vision, and robot programs.
• Experience with Siemens or Allen-Bradley PLCs and related hardware.
• Understanding of networking, control architectures, and integration with higher level systems.

Responsibilities

• Design and develop control systems architecture including PLCs, HMIs, motion controllers, and networks.
• Program and debug PLCs and HMIs based on project specifications.
• Test control components and complete systems prior to deployment.
• Collaborate with mechanical design and project teams for seamless integration.
• Support FAT/SAT processes and site commissioning at customer sites.
• Document code archives, IO lists, BOMs, and technical manuals.
• Travel up to 25% annually for commissioning, service, and support.
• Lead controls engineering efforts when requested by management.

Skills

PLC programming

HMI programming

Robot programming

Industrial networking

Documentation

Root-cause analysis

Education

Bachelor of Science in Electrical Engineering or related field

Tools

Siemens PLCs

Allen-Bradley PLCs

HMI (PanelView, etc.)

Job description

• Employee Type FT Exempt
• Required Degree 4 Year Degree
• Travel 25%
• Manage Others No

This list of duties and responsibilities is not all-inclusive and may be expanded to include other duties and responsibilities as management may deem necessary from time to time.

• Design and develop control systems architecture, including PLCs, HMIs, motion controllers, safety systems, and industrial networks.
• Program and debug PLCs (e.g., Allen-Bradley, Siemens, Omron) and HMIs based on project specifications.
• Program and fine-tune all control components, including safety devices, servo drives, process hardware, and robots, from power-up to final validation.
• Collaborate closely with mechanical designers and project teams to ensure seamless integration of controls into machine design.
• Perform in-house testing of control components and complete system testing prior to deployment.
• Participate in equipment startup, debug, and commissioning both in-house and at customer sites.
• Support FAT (Factory Acceptance Testing) and SAT (Site Acceptance Testing) processes.
• Configure, troubleshoot, and support industrial networks (e.g., Ethernet/IP, Profinet).
• Maintain comprehensive and accurate project documentation, including code archives, IO lists, BOMs, and technical manuals.
• Provide ongoing technical support to customers and internal service teams after installation.
• Complete all required project development documentation and status reports in coordination with the Project Manager.
• Serve as Lead Controls Engineer when requested by the Engineering Manager, guiding project execution and supporting team members.
• Represent the company professionally, fostering positive relationships with customers, subcontractors, vendors, and colleagues to support successful project delivery.
• Travel up to 25% annually to customer sites for commissioning, service, and support.
• Other duties as assigned.

Requirements

Education and/or Experience

• Bachelor of Science degree in Electrical Engineering, Technology, Automation Engineering, or a related field (or equivalent experience).
• 5+ years of experience in control systems activities, including familiarity with hardware design, PLC, HMI, vision systems, and robot programs.
• Working knowledge of current programmable controllers and related technologies.
• Understanding of common control and computer architecture, networking, and interfacing with higher-level computer systems.
• Experience selecting, programming, and integrating industrial control devices, sensors, PLCs, and HMIs; experience with Siemens or Allen Bradley PLCs required.
• Familiarity with a wide variety of production machinery and equipment, including robots, LVDT and pressure transducers, dispense systems, temperature controllers, DC nutrunner torque controllers, current and power meters, induction heating systems, box erectors, labelers, laser markers, and dot peen pin stampers.
• Ability to quickly identify root causes of control system or equipment issues and implement effective solutions under tight deadlines.
• Understanding project timelines, milestones, and change management to keep projects on track.
• Familiarity with relevant standards and regulations (e.g., UL508A, NFPA 79, ISO, CE) and how they apply to machine design and programming.
• Clear verbal and written communication with cross-functional teams, vendors, and customers, including the ability to explain technical concepts to non-technical stakeholders.
• Ability to work effectively as part of a multidisciplinary team including mechanical engineers, electricians, and project managers.
• Comfort working on diverse projects, from small upgrades to complex turnkey systems, and adjusting to evolving customer requirements.
• Strong dedication to understanding and meeting customer needs, especially during commissioning and post-installation support.

Summary

The Controls Engineer is responsible for analyzing customer requirements and specifications, performing electrical design of controls and power distribution, and writing and testing PLC and HMI programs. This role requires creativity and ingenuity to design custom automation solutions for machining and industrial projects. The Controls Engineer works as part of a project team, coordinating with others to ensure on-time project completion within budgetary constraints.