Senior Controls Engineer

Overview

Senior Controls Engineer - Waukesha, WI (onsite)

We are seeking a Senior Controls Engineer to join our Advanced Manufacturing team at our Corporate HQ in Waukesha, WI!

In this role you will be responsible for design, implementation and successfully scale automated and semi- automated controls systems utilizing sound engineering principles and technologies.

Develop PLC code that will interact with subsystems such as conveyors, robots, Manufacturing Execution System MES, machine vision, and 3rd party equipment.

Perform the research and development on new technologies necessary to tackle complex assembly and automation problems that have direct impact to the quality and delivery of our products.

Identify legacy controls by risk assessment, create remediation plan, and execute controls upgrade according to plan.

Use your leadership skills for direction and mentorship of machine / automation suppliers; be the driver on internal projects; serve as a technical resource to other engineering groups and project leaders, while driving standards and process improvements.

Essential Duties & Responsibilities

Develop new and or improved processes through the application of theoretical and practical engineering

Design and build out factory level, and line / machine level controls standards and specification for application by internal equipment development team and external partners

Acts as the corporate SME for plant resources on control systems programming by architecting, writing and debug PLC ladder logic / IPC SW with an emphasis on generating code that is organized, structured, documented, maintainable and reusable. PLC code will interact with subsystems such as conveyors, robots, Manufacturing Execution System MES, machine vision, part tracking systems, and 3rd party equipment.

Implement (ANSI / RIA15.06 / OSHA compliant) control reliable safety systems for safeguarding robots, gantries, conveyors, and other high volume manufacturing equipment

Generate aesthetically simple HMI screens for complex machinery while providing sufficient feedback for troubleshooting

Work with IT to connect manufacturing assets to enterprise network using established standards / guidelines

Keeps abreast of all meaningful technical trends and developments and incorporates them in appropriate assignments

Create request for Quotation / Proposal (RFQ / RFPs), Organize cross-functional reviews of the machine requirements, design, qualification and capability and engage machine suppliers for automated equipment design reviews and proposals

Travel to the machine suppliers for equipment qualification, acceptance testing and support during build events

Frequent travel to other Generac sites for support as needed. (Generally day trips)

Minimum Qualifications

Bachelor of Science Degree in Engineering, Computer Science, or related discipline

7+ years of experience with Rockwell Logix

Preferred Qualifications

Expert-level experience in design, program, integration, and validation of controls in high volume automated process equipment for discrete manufacturing using Rockwell Logix and GE RXi platforms.

Experience in designing controls hardware and OT infrastructures including a thorough understanding of Industrial Communication Protocols

Experience in creating technical specifications for automated manufacturing equipment, machine qualification requirements, design of experiments and failure analysis

Expertise in the design of machine safety circuits and programming of safety PLCs

Expertise with software and SCADA platforms to support Industry 4.0 manufacturing projects : including Historians and OPC Servers.

Experience with machine integration with common IoT platforms

Experience with SQL and Python / Java would be a plus.

Able to communicate effectively in a worldwide environment.

Previous experience with SAP or equivalent ERP.

Experience with Fanuc robotics is a plus.

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