Sr. Controls Systems Engineer (Waukesha, WI – Onsite with Flexibility)

Sr. Controls Systems Engineer (Waukesha, WI – Onsite with Flexibility)

Employment Type: Full-time
Location: Waukesha, Wisconsin (onsite; flexible remote when needed)
Compensation: $105,000 – $120,000 base + full benefits

Northwest Talent Solutions is partnering with an advanced manufacturing organization seeking a Senior Controls Systems Engineer to design, implement, and scale automated production equipment. This role sits within an Advanced Manufacturing team and directly impacts quality, throughput, and delivery performance across production operations.

This is a hands-on automation engineering position. You will architect and program control systems that integrate robotics, conveyors, machine vision, and Manufacturing Execution Systems (MES) to support high-volume manufacturing.

What You'll Do:

• Design and implement automated and semi-automated manufacturing systems

• Develop, structure, and debug PLC programs (Rockwell Logix preferred)

• Integrate equipment with robots, conveyors, machine vision, and MES platforms

• Create HMI interfaces for operators and maintenance teams

• Implement machine safety systems compliant with industrial safety standards

• Connect manufacturing equipment to enterprise and plant networks

• Perform controls upgrades and legacy equipment risk remediation

• Lead equipment qualification, factory acceptance testing (FAT), and site acceptance testing (SAT)

• Work with suppliers and internal teams on equipment design and integration

• Troubleshoot production equipment and support manufacturing launches

• Establish controls standards and support continuous improvement initiatives

Required Qualifications:

• Bachelor's degree in Engineering, Computer Science, or related technical discipline (equivalent experience considered)

• 7+ years of controls engineering experience

• Strong experience with Rockwell/Allen-Bradley PLC programming

• Experience integrating automated equipment in a manufacturing environment

• Experience with control panels, wiring, and equipment commissioning

• Ability to support plant operations and work cross-functionally with production teams

Preferred Experience:

• Robotics integration (Fanuc or similar)

• Machine vision systems

• MES, SCADA, historians, or Industry 4.0 connectivity

• Industrial communication protocols

• Safety PLCs and machine safeguarding

• SQL, Python, or similar programming exposure

• ERP connectivity (SAP or equivalent)

Ideal Background:

Candidates who have supported real production lines — including equipment builds, launches, automation upgrades, or troubleshooting live manufacturing systems — will be especially relevant. Experience coordinating vendors and performing on-site commissioning is highly valued.

Screening Questions:

Be prepared to discuss:

• PLC programming experience and platforms used

• Automation or equipment integration projects you've led

• Controls panel design, wiring, or commissioning experience

• Examples of troubleshooting production equipment or launches

Northwest Talent Solutions and our client are equal opportunity employers. Qualified applicants will receive consideration without regard to any protected status under applicable law.