Senior Manufacturing Controls Engineer

Mogi I/O : OTT/Podcast/Short Video Apps for you; Chicago (IL); On-site; USD 96,000 - 130,000; Full time

Job summary

A leading automation solutions provider is seeking a Senior Controls Engineer to design and implement automated control systems in a manufacturing environment. The ideal candidate will have at least 7 years of experience, specifically with Rockwell Logix and PLC programming. This full-time role based in Waukesha, Wisconsin offers a competitive salary of USD 96,000 – 130,000 per year, with a sign-on bonus potentially available.

Qualifications

• Minimum 7 years of experience as a Controls Engineer.
• Minimum 4+ years of hands-on experience with Rockwell Logix.
• Proven background in manufacturing automation.
• Experience in PLC and HMI programming for discrete manufacturing systems.

Responsibilities

• Design, implement, and scale automated and semi-automated control systems.
• Develop, program, and debug PLC code for subsystems.
• Architect and validate PLC and HMI code.
• Design and implement control-reliable safety systems.
• Collaborate with IT and operations to connect manufacturing assets.

Education

Bachelor's Degree in Engineering, Computer Science, or a related field

Tools

Rockwell Logix

PLC programming

HMI programming

SCADA

Python

SQL

Java

Job description

1 day ago – Be among the first 25 applicants

Location: Waukesha, Wisconsin (Onsite – Local candidates only)

Work Type: Full-Time, Permanent

Experience: 7 – 15 Years

Compensation: USD 96,000 – 130,000 per year (sign‑on bonus may be offered; relocation assistance not provided)

Eligibility: US Citizen / Green Card Holder / Permanent Resident (visa sponsorship not available)

Job Overview

Seeking an experienced Senior Controls Engineer to design, implement, and scale automated and semi‑automated control systems in a manufacturing environment. The ideal candidate will have extensive experience with Rockwell Logix, PLC programming, machine integration, and manufacturing execution systems (MES). This role involves leading automation projects, mentoring vendors, improving processes, and ensuring control system reliability and safety compliance.

Key Responsibilities

• Design, implement, and scale automated and semi‑automated control systems using sound engineering principles.
• Develop, program, and debug PLC code (Rockwell Logix / GE RXi) for subsystems such as conveyors, robots, MES, and machine vision.
• Architect, write, and validate PLC and HMI code that is organized, documented, maintainable, and reusable.
• Design and implement control‑reliable safety systems in compliance with ANSI/RIA 15.06 and OSHA standards.
• Create and maintain factory‑level and machine‑level control standards and specifications.
• Collaborate with IT and operations to connect manufacturing assets to enterprise networks.
• Serve as a technical resource and subject matter expert for controls and automation.
• Lead cross‑functional design reviews and vendor collaborations for automation projects.
• Travel to supplier or manufacturing sites for equipment qualification, FATs, and project support (primarily day trips).
• Stay current with new technologies in automation and incorporate improvements into production systems.

Must‑Have Qualifications

• Bachelor’s Degree in Engineering, Computer Science, or a related field.
• Minimum 7 years of experience as a Controls Engineer.
• Minimum 4+ years of hands‑on experience with Rockwell Logix (programming, design, integration).
• Proven background in manufacturing automation (not logistics).
• Demonstrated job stability with a consistent employment history.
• Experience in PLC and HMI programming for discrete manufacturing systems.

Nice‑to‑Have Qualifications

• Expertise in Rockwell Logix and GE RXi platforms for high‑volume automation.
• Experience designing controls hardware and OT infrastructure, including industrial communication protocols.
• Strong understanding of machine safety circuit design and safety PLC programming.
• Experience with SCADA, Historians, OPC Servers, and IoT integration.
• Familiarity with SQL, Python, or Java for data automation and analysis.
• Experience integrating controls systems with SAP or other ERP systems.
• Experience with Fanuc robotics or similar automation systems.
• Excellent communication and cross‑functional collaboration skills.

Education

Required: Bachelor of Science in Engineering, Computer Science, or related discipline.

Additional Guidelines

• Local candidates preferred (Waukesha or nearby areas).
• No frequent job changes; candidates with stable career history will be prioritized.
• Interview Process: Phone Screen → Onsite Client Interview.