Controls Engineer

Barry-Wehmiller•Sheboygan, WI

10h

About The Position

The Controls Engineer designs, develops, and supports control systems that automate industrial processes and machinery. This role performs a broad range of control design and application duties, including PLC and motion control programming, system integration, diagnostics, and documentation. The Controls Engineer works closely with cross-functional teams, customers, and suppliers to deliver reliable, high-performance machine control solutions.

Requirements

Ability to competently perform all Controls Engineer II responsibilities
Strong experience with major controls platforms such as Allen-Bradley, Siemens, Beckhoff, B&R , or equivalent
Comprehensive knowledge of control and instrumentation theory and application
Proficiency in PLC programming, motion control, and industrial automation software
Experience with microprocessor and higher-level programming languages (e.g., Visual C++ or similar)
Ability to read and interpret complex electrical control schematics and engineering drawings
Strong system integration, diagnostic, and problem-solving skills
Ability to work independently with minimal supervision
Proven ability to work in customer facilities and manage technical customer relationships
Bachelor’s degree in Electrical Engineering, Controls Engineering, or related field
Typically 4–6 years of experience in controls engineering or industrial automation

Responsibilities

Design and develop electrical and functional control system architectures and specifications for complex machinery
Implement control algorithms, PLC programs, motion control logic, and higher-level software for machine automation
Develop software data structures, HMI/terminal displays, and data communication interfaces
Create and maintain schematics, panel layouts, wiring diagrams, assemblies, and bills of material
Apply advanced troubleshooting, debugging, and diagnostic techniques to support machine operation and reliability
Develop, maintain, and document control system software related to diagnostics, data collection, and communication with peripheral equipment
Collaborate with sales, customers, service technicians, and assembly teams to define system requirements and ensure successful implementation
Serve as a technical liaison to production, service, and system suppliers during build, checkout, installation, and startup
Interface directly with customers to understand expectations, specifications, and operational needs
Research and stay current on emerging control system architectures, technologies, and industry best practices
Analyze control system malfunctions and recommend improvements to efficiency, quality, and performance
Support commissioning, startup, and upgrades of new or existing equipment and facilities
Provide input to system operation manuals and diagnostic documentation for customers and service personnel
May mentor or coach less experienced engineers
Travel to customer sites as needed to support testing, commissioning, and startup activities
Perform other duties as assigned