Staff Controls Engineer

Generac Power Systems Inc; Sussex (WI); On-site; USD 120,000 - 160,000; Full time

Job summary

Generac Power Systems Inc in Wisconsin seeks an Engineer IV – Controls (Staff Engineer) to lead new product development and continuous improvement of legacy systems. You will design, tune, simulate, and implement PLC programs and electrical system integrations to deliver robust, scalable power solutions.

Key responsibilities include defining precise functional requirements, validating designs, creating BOMs, collaborating with manufacturing partners, and mentoring junior engineers.

Qualifications

• Bachelor of Science in Electrical Engineering; 7+ years of related experience.
• Experience defining and validating functional requirements and evaluating design cost, reliability, and safety.
• Proficient in PLC programming and hardware–software integration.

Responsibilities

• Designs, validates, and brings new products to market.
• Specifies precise new product functional requirements; designs, tests and integrates complex components; evaluates cost, reliability, and safety.
• Develops fitness-for-use testing, product specifications and validation plans; creates BOMs.
• Collaborates with internal manufacturing partners, contract manufacturers, designers and product specialists to optimize designs for manufacturability.
• Mentors less experienced engineers and supports project development plans.

Skills

PLC Programming

Control Design

Systems Integration

Electrical Engineering

Education

Bachelor's in Electrical Engineering

Tools

SAP

MS 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?

Primary Purpose

The Engineer IV – Controls (Staff Engineer) 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. Additionally, candidates will facilitate product development through design, validation, and release.

Major Responsibilities

• Designs, validates, and brings new products to market.
• Specifies precise new product functional requirements; designs, tests and integrates a variety of increasingly 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 increasingly 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 increasingly complex designs for manufacturability.
• Utilizes PLC programming proficiency to develop programming instructions for optimal machine operation.
• Supports product development plans (schedule, product cost, meeting design inputs).
• Acts as a resource to mentor and teach less experienced engineers.
• Other duties as assigned.

Minimum Job Requirements

Education Bachelor of Science Degree in Electrical Engineering or related discipline; 7+ years of relevant work experience.

Certification / License

Work Experience

Knowledge / Skills / Abilities

• Designs, validates, and brings new products to market.
• Specifies precise new product functional requirements; designs, tests and integrates a variety of increasingly 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 increasingly 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 increasingly complex designs for manufacturability.
• Utilizes PLC programming proficiency to develop programming instructions for optimal machine operation.
• Supports product development plans (schedule, product cost, meeting design inputs).
• Acts as a resource to mentor and teach less experienced engineers.
• Other duties as assigned.

Preferred Job Requirements

Education

Certification / License

Work Experience

• Ability to perform detail-oriented work with a high degree of accuracy on multiple projects of increasing complexity.
• Proven expertise in developing control algorithms across diverse power control and power management applications; Expertise in closed loop tuning 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 in new product design and development; Active participant in technical communities tied to industry standards or regulations; 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; Able to solve complex engineering problems; MS Excel, MS Word; Experience with machine design; Previous experience with SAP or equivalent ERP.
• Other duties as assigned.

Physical Requirements and Working Conditions

PHYSICAL DEMANDS: Office Environment (Includes field sales): 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 up to 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. Occasional travel. (If travel percentage is required beyond occasional or is a regular part of the job, include "Up to x% travel and valid Driver's License required.")

Production Environment (Includes professionals who are active on the shop floor) (For Field Technicians): While performing the duties of this job, the employee is regularly required to stand. The employee is frequently required to use hands to manipulate objects, tools, or controls; and to talk and hear. The employee is regularly required to walk, stoop, crouch, bend and reach above shoulders. The employee must frequently lift and/or move up to 50 pounds unassisted and up to 100 pounds with assistance, waist high, up to 10 feet away. This job's specific vision abilities include close vision, distance vision, peripheral vision, and depth perception. While performing the duties of this job, the employee will be working in the typical conditions of a manufacturing environment, including seasonal variations in temperatures and occasional exposure to manufacturing fumes or byproducts. The employee must comply with the assigned location PPE requirements, including but not limited to safety glasses, hearing protection, appropriate gloves, clothing, and shields for required tasks, and closed-toed or safety shoes as required by facility safety policies. The employee must be able to work in varying weather conditions including extreme heat, snow, and ice. The employee may be required to obtain a DOT Medical Card and have the ability to drive a heavy-duty truck on a daily basis.

DISCLAIMER All responsibilities and requirements are subject to possible modification to reasonably accommodate individuals with disabilities. This job description in no way states or implies that these are the only responsibilities to be performed by an employee occupying this job or position. Employees must follow any other job-related instructions and perform any other job-related duties requested by their leaders.

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.

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?

As one of the leaders and largest suppliers of power generation equipment and technology, the work we do touches millions of lives. Employees at Generac are encouraged to be innovative and are valued as an integral part of our global team. Our challenging goals develop knowledgeable employees dedicated to helping continue Generac’s success. Generac provides individuals the opportunity to work in a fast-paced agile work environment where their work makes a difference in people’s lives and their own.