Principal Controls Engineer (Team Lead)

STELLA & CHEWY'S LLC • Oak Creek, WI

4h

About The Position

The Principal Controls Engineer is the senior technical leader of the controls department, responsible for the strategy, design, implementation, and continuous improvement of all automation and controls systems across the facility. This individual serves as the highest-level controls subject matter expert, directly manages the Controls Engineer, and provides technical direction and mentorship to the Controls Technician via a dotted-line relationship. This is a hands-on leadership role. The Principal Controls Engineer is expected to balance high-level project ownership with direct technical contribution — reviewing and approving controls designs, driving capital projects, establishing best practices and standards, and supporting manufacturing operations as the senior escalation resource for complex controls issues.

Requirements

• Bachelor of Science in Electrical Engineering, Controls Engineering, or a closely related engineering discipline.
• 8+ years of progressive controls engineering experience in a manufacturing environment.
• Advanced proficiency in PLC programming (Allen-Bradley ControlLogix / CompactLogix preferred; Siemens, Omron, or equivalent considered).
• Strong experience with HMI/SCADA development (FactoryTalk View, Ignition, or equivalent).
• Working knowledge of industrial networking: EtherNet/IP, DeviceNet, Profibus, Modbus.
• Experience leading controls scope on capital projects, including vendor management and commissioning.
• Demonstrated ability to lead and develop technical staff.
• Proficiency with controls documentation tools (AutoCAD Electrical, EPLAN, or equivalent).

Nice To Haves

• Certified Automation Professional (CAP) or equivalent industry certification.
• Familiarity with food & beverage or process manufacturing environments.
• Experience with MES, OEE platforms, or historian systems (OSIsoft PI, Ignition Perspective).
• Six Sigma, Lean Manufacturing, or formal reliability engineering (RCM/FMEA) background.

Responsibilities

• Establish and maintain controls engineering standards, including PLC/HMI programming conventions, network architecture, panel design standards, and documentation requirements.
• Serve as the technical authority for all controls-related decisions, including platform selection, system architecture, and change management.
• Lead root cause analysis and corrective action for complex or recurring controls-related failures.
• Ensure all controls systems are designed and maintained to applicable electrical codes, NFPA 70E, and industry safety standards.
• Directly supervise the Controls Engineer, including goal-setting, performance reviews, and professional development planning.
• Provide technical direction, mentorship, and skill development to the Controls Technician via a dotted-line relationship, in coordination with the Maintenance Supervisor.
• Build and sustain a high-performing controls team; support recruiting and onboarding as the department grows.
• Lead or co-lead controls scope for capital projects from concept through commissioning, including scope definition, vendor selection, design review, FAT/SAT, and startup support.
• Develop and maintain controls engineering project documentation: P&IDs, loop diagrams, I/O lists, control narratives, and as-built drawings.
• Evaluate, select, and manage controls system vendors and integrators.
• Champion automation opportunities to improve OEE, reduce manual labor, and enhance product quality.
• Serve as the senior technical escalation point for controls issues affecting production; available for critical off-hours support on major failures.
• Create controls preventive maintenance program, including PLC backup schedules, drive calibrations, and instrument calibration intervals.
• Maintain and continuously improve the controls system documentation library, including program archives, network diagrams, and spare parts inventory.
• Partner with Production, Maintenance, and Quality to identify and resolve controls-related reliability and quality issues.
• Develop and deliver electrical troubleshooting training for Maintenance Technicians spanning basic electrical fundamentals (voltage verification, motor checks, continuity and insulation/short-to-ground testing) through advanced controls diagnostics (PLC I/O faults, drive diagnostics, and controls panel troubleshooting); build skills within the broader maintenance team to reduce dependency on controls specialists for routine electrical issues.
• Ensure controls designs and modifications comply with applicable codes including NFPA 70, NFPA 79, and applicable machine safety standards (ISO 13849/IEC 62061).
• Support site safety programs including LOTO, arc flash analysis, and electrical safety training for controls personnel.
• Maintain accurate as-built documentation and control panel labels consistent with NFPA 79 requirements.

What This Job Offers

• Job Type: Full-time
• Career Level: Senior