Senior Controls Engineer

Wunderlich-Malec Careers•Philadelphia, PA

67d•Hybrid

About The Position

Wunderlich-Malec Engineering (WM) is a 100% employee-owned ESOP and one of the largest and most well-established engineering companies in the United States. When you join WM you become part of a company that is: 100% employee-owned with 40+ years of industry history ENR (Engineering News Record) Top 500 firm Rated as a top System Integrator Giant. We have a Senior Controls Engineer position available in Philadelphia, PA. This person will play a critical role in designing and implementing advanced Emerson DeltaV and/or Rockwell automation solutions for the Life Sciences industry. Working within a dynamic system integration environment, you will be part of a team responsible for delivering high-quality, fit-for-purpose, regulatory-compliant automation that supports biopharmaceutical and small molecule API manufacturing. This is an opportunity to contribute to projects that impact global healthcare while growing within an employee-owned organization that values innovation and technical excellence. You will have the opportunity to work in one of our local offices while supporting global clients, delivering cutting-edge automation solutions in the industry.

Requirements

Proficiency in ISA-88 Batch Processing and DeltaV Batch configuration
Familiarity with Historian, Alarm Management, and Advanced Control Strategies
Experience with automation protocols (HART, Foundation Fieldbus, Profibus, Modbus TCP/IP, Ethernet/IP, OPC)
Expertise in process control strategies, loop tuning, and system integration
Understanding of industrial networking for communication between controllers, servers, and HMIs
Knowledge of GAMP5, cGMP, 21 CFR Part 11, and validation life cycle processes
Strong troubleshooting skills and the ability to diagnose and resolve complex automation issues
Experience in translating high-level functional requirements into detailed software design
Ability to work independently and collaboratively on complex automation projects in industrial and manufacturing environments
Strong written and verbal communication skills for technical documentation and collaboration with cross-functional teams and clients.
Passion for quality craftmanship, innovation and problem-solving in mission-critical environments
Willingness to travel up to 30% annually for on-site support and commissioning and/or participate in multiple months of remote onsite rotational support
Valid driver’s license and international passport (or ability to obtain quickly)
Ability to stand and move around job sites for up to 8-12 hours per shift
Ability to frequently climb up and down stairs and ladders
Ability to maintain balance and stability while performing tasks at heights
Ability to occasionally lift, carry, and move objects up to 40 pounds as required
Ability to hear and communicate with clear speech in industrial environments
Ability to drive vehicles and operate simple machinery, with proper training, such as lifts
Frequent reaching, bending, stooping, crouching, or crawling in and around machinery and production equipment as required during project commissioning and startup activities
Manual dexterity is sufficient to operate tools, instruments, or computer equipment
The ability to wear required personal protective equipment (PPE) such as safety glasses, gloves, hard hats, and steel-toed boots
Visual acuity, seeing color, and hand-eye coordination required for inspection, troubleshooting, and detailed technical work
Working around construction and industrial production equipment and personnel
Exposure to manufacturing environments with moderate to high noise levels, temperature fluctuations, moving mechanical parts, and industrial chemicals.
Electrical/Instrumentation, device checkout and troubleshooting, including voltage testing, troubleshooting equipment on a ladder, and light electrical assembly (e.g., signal wiring in control panels/instruments).
Construction trailer and Data Center environment.
Frequent PC and cell phone usage.
Typical Personnel Protective Equipment (PPE) Required: Safety Glasses, Steel Toed shoes, hearing protection, and electrical safety PPE.
Employees must comply with customer specific requirements and PPE.

Nice To Haves

Familiarity with Rockwell Automation, Siemens PCS7, or other PLC/DCS/SCADA systems is a plus
Working experience in the Life Sciences industry, including biotechnology, pharmaceuticals, or medical devices is preferred, but not required if strong Emerson DeltaV experience from other industries
Familiarity with electrical design principles and working knowledge of AutoCAD is a plus

Responsibilities

Develop, configure, and implement Emerson DeltaV control systems, ensuring alignment with customer specifications, Wunderlich-Malec (WM) standards, and industry best practices
Design and program Batch processes per ISA-88 standards (including Emerson DeltaV)
Collaborate with clients in the life sciences industry to gather requirements and develop customized automation solutions
Engineer system architecture, hardware specifications, and control strategies to optimize manufacturing efficiency
Configure controllers, applications, HMI, and historian solutions while ensuring compliance with GAMP 5, cGMP, and 21 CFR Part 11 regulations
Conduct Factory Acceptance Testing (FAT) and Site Acceptance Testing (SAT) to validate system performance
Instrument specification, wiring, troubleshooting, and calibration.
Develops and/or redlines control drawings and electrical schematics detailing control system configuration, major hardware and wiring, and design of control panel layouts.
Provide on-site startup, commissioning, and troubleshooting support activities for deployed systems into production environments
Ensure compliance with system and software development life cycle methodologies, including validation documentation
Work closely with multidisciplinary teams, including electrical engineers, process engineers, validation engineers, and project managers, to deliver projects on time and within budget
Mentor junior engineers and technicians, fostering knowledge-sharing and technical growth
Participates in proposals and writes sections of proposals as directed by others
Independently prepares proposals for small projects
Provides support in developing estimates for project proposals
Leads customer staff meetings when it affects assigned design tasks
Identifies opportunities to build relationships with client peers
Fields customer requests and evaluates them vs defined scope
Identifies potential customer needs and develops proposal or change order options for review
Project managing simple to moderately complex projects.
Prepares project execution plans
Develops and communicates Status Reports, Earned Value Reports, Estimate to Complete Reports, and Committed Cost Reports for small to medium size projects
Identifies project risks and develops risk management plan
Prepares level 2 project schedules with dependencies
Manages budget, effort, change orders, invoicing, and variances