Senior Controls Engineer

Wunderlich-Malec Engineering has a Senior Controls Engineer opportunity 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.

Essential Duties and Responsibilities The following responsibilities are essential to the satisfactory performance of this role. Reasonable accommodation may be made as needed:

• Develop, configure, and implement Emerson DeltaV control systems, ensuring alignment with customer specifications, Wunderlich-Malec (WM) standards, and industry best practices (Familiarity with Rockwell Automation, Siemens PCS7, or other PLC/DCS/SCADA systems is a plus)
• 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. This effort includes the ability to architect and specify control system designs and give work direction to technicians creating the drawings
• 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

• 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
• 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
• Knowledge of GAMP5, cGMP, 21 CFR Part 11, and validation life cycle processes
• Familiarity with electrical design principles and working knowledge of AutoCAD is a plus
• Strong troubleshooting skills and the ability to diagnose and resolve complex automation issues
• Experience in translating high-level functional requirements into detailed software design
• Familiarity with Rockwell Automation, Siemens PCS7, or other PLC/DCS/SCADA systems is a plus
• 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

• 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 evaluat