Senior Controls Engineer

Generac; Waukesha (WI); On-site; USD 95,000 - 130,000; Full time

Job summary

Generac is seeking a Senior Controls Engineer to join our Advanced Manufacturing team in Waukesha, WI. This role involves designing and implementing automated control systems, developing PLC code for manufacturing subsystems, and ensuring process improvements for quality and delivery. Candidates must have a Bachelor's degree in Engineering and 7+ years of relevant experience, particularly with Rockwell Logix.

Qualifications

• 7+ years of experience with Rockwell Logix required.
• Expertise in controls design and safety PLC programming.
• Experience with SCADA platforms supporting Industry 4.0 projects is preferred.

Responsibilities

• Design and implement automated controls systems.
• Develop PLC code and ensure compliance with safety standards.
• Mentor suppliers and project leaders for process improvements.

Skills

Controls design

Programming

Validation

Problem-solving

Effective communication

Education

Bachelor’s degree in Engineering or Computer Science

Job description

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We are Generac, a leading energy technology company committed to powering a smarter world.

Over the 60 plus years of Generac’s history, we’ve been dedicated to energy innovation. From creating the home standby generator market category, to our current evolution into an energy technology solutions company, we continue to push new boundaries.

Generac is seeking a Senior Controls Engineer to join our Advanced Manufacturing team at our Corporate HQ in Waukesha, WI!

In this role, you will be responsible for designing, implementing, and scaling automated and semi-automated controls systems utilizing sound engineering principles and technologies.

Develop PLC code that will interact with subsystems such as conveyors, robots, Manufacturing Execution System (MES), machine vision, and 3rd party equipment.

Perform research and development on new technologies necessary to tackle complex assembly and automation problems that impact the quality and delivery of Generac products.

Identify legacy controls by risk assessment, create remediation plans, and execute controls upgrades accordingly.

Use leadership skills for direction and mentorship of machine/automation suppliers; lead internal projects; serve as a technical resource to other engineering groups and project leaders, while driving standards and process improvements.

Essential Duties & Responsibilities:

• 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 internal and external teams.
• Architect, write, and debug PLC ladder logic/IPC software, ensuring code is organized, structured, documented, maintainable, and reusable. Interact with subsystems such as conveyors, robots, MES, machine vision, part tracking, and 3rd party equipment.
• Implement ANSI/RIA15.06/OSHA compliant control safety systems for safeguarding robots, gantries, conveyors, and other high-volume manufacturing equipment.
• Create simple yet effective HMI screens for complex machinery, providing troubleshooting feedback.
• Coordinate with IT to connect manufacturing assets to enterprise networks using established standards.
• Stay updated on technical trends and incorporate relevant innovations.
• Prepare RFQ/RFP documents, organize cross-functional reviews, and engage suppliers for equipment design and qualification.
• Travel to supplier sites for equipment qualification, acceptance testing, and support during build events.
• Support other Generac sites as needed, primarily via day trips.

Minimum Qualifications:

• Bachelor’s degree in Engineering, Computer Science, or related field.
• 7+ years of experience with Rockwell Logix.

Preferred Qualifications:

• Expertise in controls design, programming, and validation for high-volume automated processes using Rockwell Logix and GE RXi.
• Experience designing controls hardware and OT infrastructure, including industrial communication protocols.
• Proficiency in creating technical specifications, machine qualification, and failure analysis.
• Expertise in designing safety circuits and programming safety PLCs.
• Experience with SCADA platforms (Historians, OPC Servers) supporting Industry 4.0 projects.
• Knowledge of machine integration with IoT platforms.
• Experience with SQL, Python, or Java is a plus.
• Effective communication skills in a global environment.
• Previous experience with SAP or similar ERP systems.
• Experience with Fanuc robotics is advantageous.

Knowledge, Skills, & Abilities:

• Ability to work independently with occasional guidance.
• Deep technical expertise and broad knowledge base.
• Utilize best practices and external/internal insights to enhance products/services.
• Strong conceptual, visualization, and creative skills.
• Excellent time management, prioritization, and problem-solving skills.
• Ability to solve complex problems and make decisions effectively.
• Potential to lead cross-functional teams and mentor colleagues.
• Ownership of designs and participation in standards development.
• Focus on improving engineering’s financial impact and understanding of cross-functional influences.

Physical Demands: Regular talking, hearing, manual manipulation, standing, walking, occasional stooping, bending, reaching, and lifting up to 50 pounds. Frequent computer use, close vision, and focus adjustments. Occasional travel.

We are an equal opportunity employer and all qualified applicants will receive consideration regardless of race, color, religion, sex, sexual orientation, national origin, disability, veteran status, or other protected characteristic.

Senior-level

• Mid-Senior level

Employment type

• Full-time

Job function

• Engineering and IT

Industry

• Electric Power Generation

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