PLC Engineer

Creative Solutions Services, LLC; Waukesha (WI); On-site; USD 85,000 - 110,000; Full time

Job summary

Creative Solutions Services, LLC in Wisconsin is seeking a skilled test/controls engineer to lead design, testing, and optimization of capital equipment and processes. You will guide test equipment selection, develop specifications, and ensure compliance with safety and OSHA standards.

The role emphasizes problem solving, project management, and collaboration across Manufacturing, Quality, EHS, and Engineering to drive continuous improvement using Lean/Six Sigma approaches.

Qualifications

• Bachelor's degree in engineering/computers/Math/Science from an accredited institution.
• Minimum 3 years of test/controls engineering experience.
• Must be legally authorized to work in the US without company sponsorship.
• Experience with programming software such as Visual Basic/Studio, SQL and other Microsoft apps; Rockwell RS software.
• NI LabVIEW and NI TestStand experience.
• Experience with PLC, HMI programming and safety systems design.
• Project Management experience.

Responsibilities

• Provide guidelines for the design and selection of test equipment, testing protocols, test data collection programs and best practices.
• Support, service, and troubleshoot test equipment and electrical systems within the plant.
• Develop test equipment specifications ensuring compliance with electrical safe work practices and OSHA requirements.
• Enforce safety expectations and communicate hazards to ensure zero-incident culture and product conformance.
• Collaborate with manufacturing, MESH, manufacturing engineering, quality, product design engineering, suppliers, and customers as needed.
• Perform root cause and failure analysis; teach others in critical thinking and problem solving.
• Guide and instruct the capital equipment selection process and evaluate CARs for major new products/projects.
• Lead assessment processes and act as a category lead during assessments.
• Lead cost-out initiatives and drive continuous improvement using Lean and Six Sigma; monitor metrics.
• Leverage advanced technology to improve information systems for testing/controls.
• Lead projects, define goals, budgets, and WBS; coordinate cross-functional resources and communication plans.
• Implement sustained change management using ADKAR and MOC processes.

Skills

Problem solving

Project Management

Root cause analysis

Lean/Six Sigma

Education

Bachelor's degree in engineering/computers/Math/Science

Tools

Rockwell Software RS/FactoryTalk

RS Logix 5/500/5000

Studio 5000

FactoryTalk View ME/SE

VB6

NI LabVIEW

NI TestStand

PLC/HMI programming

Safety systems design

Job description

Job Description & Skill Requirement:
Essential Functions:

• Provide guidelines for the design and selection of test equipment, testing protocols, test data collection programs and best practices.
• Support, service, and trouble shoot test equipment and electrical systems within the plant
• Develop test equipment specifications ensuring compliance with electrical safe work practices and OSHA requirements. Identify potential safety hazards and provides input into the remediation process, ensuring equipment functionality meets required specifications.
• 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.
• Work with manufacturing, MESH, manufacturing engineering, quality, product design engineering, suppliers, and customers as needed.
• Performs root cause and failure analysis. Applies critical thinking and problem-solving skills to provide specified cost, quality, and performance in a safe and efficient manner. Teaches others in critical thinking and problem solving.
• Guide and instruct the capital equipment selection process. Develop and evaluate Capital Appropriation Requests (CAR's) for major new product or process programs and initiatives related to testing/controls.
• Active role in assessment processes within manufacturing environment. May act as a category lead or champion during an assessment process.
• Lead/co-lead cost-out initiatives and promotes culture of continuous improvement. Collaborates with teams that leverage the use of Lean and/or Six Sigma tools to solve problems within manufacturing. Drives initiatives to closure and monitors/drives associated metrics. Participates in Continuous Improvement Kaizens/BPIs as appropriate to the facility.
• Leverages advanced technology and innovation to improve the use and effectiveness of information systems for testing/controls.
• Seeks opportunities to eliminate waste associated with the flow of factory floor test information. Leads projects, develops project goals, budgets, and work breakdown structures. Proactively aligns cross functional resources such as Production, Quality, EHS, Maintenance, Engineering, and contractors/vendors to ensure that project goals are met. Develops and executes communication plans among project/program working groups, associated leadership teams, and other stakeholders.
• Responsible for executing sustained change management as it applies to processes within manufacturing operations. Utilizes change management techniques such as ADKAR to effectively drive and sustain process improvements and usage of MOC (management of change) process.

Basic Qualifications:

• Bachelor's degree in engineering/computers/Math/Science from an accredited institution
• Minimum 3 years of test/controls engineering experience
• Must be legally authorized to work in the US without company sponsorship
• Experience in many computer programing software such as visual basic/studio, SQL, and other Microsoft applications. Rockwell Software (RS and Factory Talk)
  RS Logix 5, RS Logix 500, RS Logix 5000, Studio 5000, FactoryTalk View ME, FactoryTalk SE, VB6,
• NI LabVIEW and NI Test Stand
• Experience with PLC, HMI programming, and safety systems design.
• Project Management experience

Preferred Qualifications:

• +5 years Controls/Test engineering experience.
• Understanding of problem-solving methodologies used in determining root cause and formulating corrective action(s) - i.e., thought maps, 8D, root cause analysis, Process Failure Mode Effect Analysis, control charts, Pareto charts, A3s, etc.
• GB (green belt) or BB (black belt) certified.
• Experience in electrical testing procedures and protocols.
• Fundamental knowledge of electrical equipment at component and integrated system levels.

Qualification:

• Engineering Degree or related technical degree.