Senior Staff Controls Engineer

generac; Sussex (WI); On-site; USD 110,000 - 160,000; Full time

Job summary

Generac is seeking a Senior Staff Controls Engineer to lead control design and system integration for new products and legacy improvements. This field-based role requires deep expertise in control algorithms, model-based design, and rigorous testing to deliver reliable power solutions.

You will collaborate with manufacturing, design, and product teams, mentor less-experienced engineers, and travel up to 80% to customer sites and suppliers.

Qualifications

• BS in Electrical or Mechanical Engineering or related discipline.
• 10+ years of relevant work experience.
• Experience with control design, testing, and product development.

Responsibilities

• Designs, validates, and brings new products to market.
• Specifies functional requirements; evaluates cost, reliability, and safety.
• Develops tests and plans for complex products/components.
• Collaborates with manufacturing partners to optimize designs for manufacturability.
• Mentors less experienced engineers; travels as required.

Skills

Control algorithms

Closed-loop control

Model-based design

HIL/SIL testing

Regulatory experience

Technical mentorship

Strong communication

ERP/ERP experience

Leadership

Education

Bachelor's degree in Electrical/Mechanical Eng

Master's degree in control engineering

Tools

SAP

Excel

MS Word

Job description

We believe power is a promise - a shared commitment to be there for others when it matters most.

For more than 65 years, we've turned big ideas into solutions that help protect homes, strengthen businesses and build a more resilient, efficient, sustainable energy future.

Ready to Power a Smarter World with us?

The Senior Staff Controls Engineer role is field-based and is responsible for providing expertise regarding new product development as well as continuous improvement of legacy systems. Day to day responsibilities include control design and tuning, simulation development, PLC programming, and electrical system integration.

Major Responsibilities

• Designs, validates, and brings new products to market.




• Specifies precise new product functional requirements; designs, tests and integrates complex components to produce final designs; and evaluates the design's overall effectiveness, cost (including cost/benefit analysis), reliability (risk analysis), and safety.




• Designs, develops, executes and evaluates fitness-for-use testing, product specifications and process validation plans for a variety of complex products and/or components; creates and reviews material part specifications and bills of materials.




• Collaborates with internal manufacturing partners, contract manufacturers, designers and product specialists to optimize complex and advanced designs for manufacturability.




• Supporting product development plans (schedule, product cost, meeting design inputs)




• Acts as a resource to mentor and teach less experienced engineers




• 80% travel required.




• Other duties as assigned.

Minimum Job Requirements

• Bachelor of Science Degree in Electrical Engineering or Mechanical or related discipline.




• 10+ years of relevant work experience;

Knowledge / Skills / Abilities

• Ability to perform detail-oriented work with a high degree of accuracy on multiple, complex projects,




• Proven expertise in developing control algorithms across diverse power control and power management applications.




• Expertise in closed loop control tuning, stability analysis, and performance optimization of advanced control algorithms.




• Expertise in model-based design methodologies, including development of high-fidelity system simulations, automated design verification and production-ready auto code generation.




• Experience in test & validation plan and procedure development and execution including multiple methods (HIL/SIL, bench component and/or system testing, fault injection methods, etc.);




• Experience sitting on a regulatory committee in a technical role.




• Strong written communication and presentation skills.




• Ability to translate technical information to all audiences.




• Applies engineering knowledge and experience to improve products, services and processes.




• MS Excel, MS Word.




• Experience with machine design.




• Previous experience using SAP or equivalent ERP

Preferred Job Requirements

• Master’s degree in electrical or mechanical engineering with focus on control engineering.

Knowledge / Skills / Abilities

• Works independently, with guidance in only the most complex technical issues




• Requires specialized in-depth knowledge and/or breadth of expertise.




• Interprets internal or external business issues and recommends solutions / best practices, strong business acumen




• Solves complex problems




• Takes a broad perspective to identify solutions




• Strong decision-making skills




• May lead small- to medium-sized cross-functional technology development teams to achieve milestones and objectives.




• Ensure success cross-functionally.




• Coaches and mentors less experienced engineers.




• Offer recommendations and implement solutions.




• Take ownership of designs




• Is recognized as an expert in own area within the organization.




• Writes standards and procedures




• Leading efforts to improve the financial impact of engineering and related cross-functions on the business




• Excellent conceptualization, visualization, and creativity




• Excellent time management, prioritization, and analytical problem solving

Physical Demands: While performing the duties of this job, the employee is regularly required to talk and hear; and use hands to manipulate objects or controls. The employee is regularly required to stand and walk. On occasion, the incumbent may be required to stoop, bend, or reach above the shoulders. The employee must occasionally lift upto 25 pounds. Specific conditions of this job are typical of frequent and continuous computer-based work requiring periods of sitting, close vision, and the ability to adjust focus. Up to 80% travel and valid Driver’s License required.

“We are an equal opportunity employer and all qualified applicants will receive consideration for employment without regard to race, color, religion, sex, sexual orientation, national origin, disability status, protected veteran status, or any other characteristic protected by law.”