Senior Controls Engineer: Lead PLC & Vision Systems

CyberCoders, Inc.

West Bend (WI)

On-site

USD 95,000 - 130,000

Full time

14 days+

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Benefits offered by this job

Health insurance

Vision plan

Dental plan

PTO

401K

Paid holidays

Job summary

CyberCoders, Inc. seeks a Sr. Controls Engineer to design, develop, and commission control systems for automated manufacturing equipment, delivering robust PLC and HMI solutions and integrating vision systems.

You will lead technical controls work, troubleshoot complex issues, and collaborate with cross-functional teams to hit production, quality, and safety targets. You will also coordinate with vendors, mentor junior staff, and participate in FAT/SAT, site commissioning, and cybersecurity best

Qualifications

5+ years designing, programming, and commissioning industrial control systems.
Strong experience with Allen-Bradley PLCs and Studio 5000/RSLogix.
Proven ability to design and deploy HMI solutions and machine vision integration.
Willingness to travel to customer sites for commissioning.

Responsibilities

Lead design and development of PLC control systems using Allen-Bradley platforms (Studio 5000/RSLogix).
Architect, configure, and deploy HMI solutions (FactoryTalk/PanelView or equivalent) for operator interfaces and diagnostics.
Integrate and commission machine vision systems (e.g., Cognex, Keyence) for part detection, inspection, and guidance.
Develop control system I/O lists, ladder logic, structured text, function block diagrams, and motion/servo control routines.
Create and maintain electrical schematics, control wiring diagrams, and panel layouts in collaboration with electrical designers.
Perform FAT/SAT, site commissioning, and hands-on troubleshooting to resolve complex hardware, software, and communication issues.
Implement industrial network configurations (Ethernet/IP, DeviceNet, Modbus) and ensure reliable device communications and cybersecurity best practices.
Work with mechanical, manufacturing, and quality teams to ensure controls meet functional requirements and production performance targets.
Write clear technical documentation, test plans, and as-built drawings; train operators and maintenance personnel.
Drive continuous improvement projects to increase equipment uptime, reliability, and efficiency; mentor junior engineers and technicians.
Coordinate with vendors and integrators for procurement, acceptance testing, and support of control components and vision equipment.
Ensure compliance with safety standards and company procedures during design, installation, and commissioning activities.