Controls EngineerSteele Solutions • Milwaukee, WI, US

Controls Engineer

Steele Solutions • Milwaukee, WI, US

30+ days ago

Job type

Full-time

Job description

Job Description

Steele Solutions, Inc. is the nation's leading designer and manufacturer of steel work platforms and mezzanines. We recently launched our automation division to solve one of the biggest challenges in material handling-controls that are too often rebuilt from scratch, full of delays, and unpredictable at startup. With this launch, we’re looking for Control Engineer professionals to join our automation team i n Atlanta, GA (preferred) or Milwaukee, WI!

Role does require travel up to 30%

Summary

Under minimal supervision, the Controls Engineer leads the design, programming, and deployment of complex control systems for material handling automation while also serving as the technical owner of Steele Solutions’ emulation and virtual commissioning platform. The position oversees full project scopes from design through commissioning, develops and maintains reusable Emulate3D (or equivalent) component libraries, and defines PLC-to-emulation I / O standards to make virtual commissioning the default path for FAT, code QA, training, and design validation. This role provides hands-on support for PLC / HMI delivery (Rockwell / Beckhoff + Ignition), drives standardization, supports troubleshooting escalations, mentors engineers in model-driven testing, and collaborates across Mechanical and Electrical teams to reduce on-site time, risk, and cost.

System Architecture, Standards & Tooling

Design and develop PLC and HMI architectures for moderately to highly complex automation systems.

Contribute to and maintain reusable PLC / HMI code libraries, configuration templates, and engineering standards.

Define and manage the I / O contract between PLC libraries (UDTs / AOIs / DUTs) and emulation objects, including virtual-mode hooks and diagnostic structures.

Ensure alignment between standard PLC / HMI libraries and the emulation component catalog, including version control, migration notes, and Git / GitHub workflows.

Emulation Platform Ownership

Build, maintain, and expand a reusable emulation component catalog (transport, merges, gapping, scanning, diverters, recirculation; roadmap to advanced sortation).

Establish and document fidelity guidelines, modeling assumptions, and limits.

Develop automated FAT harnesses (scripted test decks, pass / fail gates, reporting) tied to design documents and performance metrics.

Create layout assembly tools and workflows to rapidly build or reconfigure models from ECAD / CAD.

Ensure parity between emulated and live systems to reduce onsite time, cost, and risk.

Technical Leadership & Execution

Program, test, and commission control systems—including conveyors, merges, and moderate sortation logic—both virtually and on-site.

Lead FAT / SAT activities, troubleshooting escalations, and commissioning strategies.

Develop and maintain proper deliverable documentation, version control, and quality assurance processes.

Contribute targeted PLC / HMI development such as device AOIs, diagnostics, Ignition widgets, gateway scripts, and position tracking.

Cross-Functional & Customer Collaboration

Serve as a technical point of contact and coordinate integration across Mechanical, Electrical, and Software disciplines.

Define CAD “markup” standards (mass, friction, materials, sensor faces, elevations) to improve model fidelity and reduce rework.

Partner with Project Management and Sales to scope projects, establish acceptance criteria, and present emulation results to internal and external stakeholders.

Provide direction and oversight to subcontractors and integration partners.

Team Development, Mentorship & Culture Building

Mentor engineers through hands-on guidance, structured peer reviews, onboarding, and training.

Deliver playbooks, “golden example” projects, and internal training materials that enable engineers to build and extend emulation models independently.

Promote a simulation-first, standards-driven culture focused on measurable outcomes such as hours saved, defects prevented, and accuracy versus on-site results

Strategic Growth & Innovation

Identify and lead improvement initiatives related to commissioning efficiency, code reusability, testing accuracy, and HMI experience.

Pilot new tools, features, or platforms that enhance controls engineering and emulation capabilities.

Contribute to internal R&D efforts and share findings that influence roadmap development and engineering best practices.

Education and / or Experience

Bachelor's degree in Electrical Engineering, Mechatronics, or related field.

Currently seeking two senior levels :

5–7 years of experience in industrial controls engineering, including lead project responsibilities.

7+ years in industrial controls or virtual commissioning, including hands-on PLC / HMI work and model-based testing.

Demonstrated experience leading emulation / virtual commissioning efforts tied to real PLC code (not visualization only).

Technical Skills

PLC Programming : Advanced proficiency in Rockwell Studio 5000 (AOIs / UDTs / ST); experience with TIA Portal; Beckhoff TwinCAT (ST / POUs / DUTs) a plus.

Emulation & Digital Twins : Strong experience with Emulate3D or equivalent—custom component catalogs, scripted test decks, virtual-mode diagnostics, and automated FAT harnesses.

HMI / SCADA : Ignition (Perspective / Vision), FactoryTalk View; alarm configuration, historian basics, security (roles / IdP).

Industrial Networks & Devices : Ethernet / IP (preferred), Profinet, OPC UA; VFDs, servo drives / motion, scanners, safety systems, and device-level diagnostics.

Tooling & Automation : Git / GitHub workflows, semantic versioning, release notes; ability to script / automate tasks using C# or Python for test / data workflows.

Data & Analysis : Familiarity with operational KPIs (throughput, gaps, divert accuracy, MTBF), basic SQL and time-series queries; ability to validate system performance with data.

Leadership & Professional Skills

Systems thinker with the ability to break down complex controls and emulation challenges into clear, testable components.

Strong communicator, effective with customers, vendors, and cross-functional engineering teams.

High documentation discipline with strong version-control awareness and adherence to engineering standards.

Proven ability to manage multiple projects simultaneously while mentoring and developing junior engineers.

Collaborative leadership style with a focus on measurable outcomes, continuous improvement, and cross-team alignment.

Ability to read and interpret technical specifications, professional journals, and engineering drawings, skilled in writing clear reports and documentation.

Willingness to travel 15–30% for commissioning, installations, and on-site support. Surge periods around major go-lives (1–3× / year) may require short, focused trips, including occasional evenings / weekends depending on customer constraints.

Physical Demands

The physical demands described here are representative of those that must be met by an employee to successfully perform the essential functions of this job. Reasonable accommodation may be made to enable individuals with disabilities to perform the essential functions.

Requires the use of hearing and eye protection when in the plant. While performing the duties of this job, the employee is regularly required to sit and use hands to finger, handle, or touch objects, tools, or controls. The employee frequently is required to talk or hear. The employee is occasionally required to stand; walk; reach above shoulders; climb or balance; and stoop, kneel, or crouch. The employee must occasionally lift and / or move up to 25 pounds. Specific vision abilities required by this job include close vision and the ability to adjust focus.

Work Environment

The work environment characteristics described here are representative of those an employee encounters while performing the essential functions of this job. Reasonable accommodation may be made to enable individuals with disabilities to perform the essential functions

The position works in an office environment – location Atlanta, GA (preferred) / Milwaukee WI, Remote to office

Travel-Up to 30%

Why You’ll Love Working Here?

A collaborative culture.

Opportunities to make a real impact as we grow.

Competitive pay, great benefits, and a great team.

Celebrations, volunteer days, and moments that make work more than just “work.”..

Are You Ready to Join the SSi Team?

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Controls Engineer • Milwaukee, WI, US

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