Lead Automation Controls Engineer

2 weeks ago

Waukesha, Wisconsin, United States Generac Full time

About Generac:

At Generac, we are dedicated to creating a safer, more efficient world. Our mission is to inspire positive change and foster innovation within the industry, ensuring our diverse team collaborates effectively to deliver reliable products and exceptional support to our global clientele.

Position Overview:

We are currently seeking a Senior Controls Engineer to enhance our Advanced Manufacturing division. This role is pivotal in designing, implementing, and scaling automated and semi-automated control systems, leveraging sound engineering principles and cutting-edge technologies.

Key Responsibilities:

  • Design and develop PLC code that interfaces with various subsystems, including conveyors, robotics, Manufacturing Execution Systems (MES), machine vision, and third-party equipment.
  • Conduct research and development on innovative technologies to address complex assembly and automation challenges, directly influencing the quality and delivery of Generac products.
  • Perform risk assessments on legacy control systems, formulate remediation strategies, and execute control upgrades accordingly.
  • Utilize leadership capabilities to mentor machine and automation suppliers, drive internal projects, and serve as a technical resource for engineering teams and project leaders.

Essential Duties:

  • Enhance processes through theoretical and practical engineering applications.
  • Establish factory-level and machine-level control standards and specifications for internal development teams and external partners.
  • Act as the corporate Subject Matter Expert (SME) for control systems programming, focusing on organized, structured, and maintainable PLC ladder logic and IPC software.
  • Implement ANSI/RIA15.06/OSHA compliant safety systems for safeguarding high-volume manufacturing equipment.
  • Create user-friendly HMI screens for complex machinery, ensuring adequate feedback for troubleshooting.
  • Collaborate with IT to connect manufacturing assets to the enterprise network, adhering to established standards.
  • Stay updated on significant technical trends and incorporate relevant advancements into projects.
  • Prepare Requests for Quotation/Proposal (RFQ/RFPs), organize cross-functional reviews, and engage machine suppliers for design assessments.
  • Travel to machine suppliers for equipment qualification and acceptance testing as necessary.
  • Frequent travel to various Generac sites for support as required.

Qualifications:

  • Bachelor's degree in Engineering, Computer Science, or a related field.
  • Minimum of 7 years of experience with Rockwell Logix.

Preferred Qualifications:

  • Expertise in designing, programming, integrating, and validating controls for high-volume automated processes using Rockwell Logix and GE RXi platforms.
  • Experience in designing control hardware and operational technology infrastructures, with a solid understanding of Industrial Communication Protocols.
  • Proficiency in creating technical specifications for automated manufacturing equipment and conducting failure analysis.
  • Expertise in machine safety circuit design and safety PLC programming.
  • Familiarity with software and SCADA platforms to support Industry 4.0 initiatives.
  • Experience with machine integration into common IoT platforms.
  • Knowledge of SQL and Python/Java is advantageous.
  • Strong communication skills in a global environment.
  • Previous experience with ERP systems is a plus.
  • Familiarity with Fanuc robotics is beneficial.

Skills and Abilities:

  • Ability to work independently while addressing complex technical issues.
  • In-depth knowledge and expertise in relevant fields.
  • Utilization of best practices to enhance products and services.
  • Strong analytical problem-solving and decision-making skills.
  • Ability to visualize and conceptualize complex ideas.
  • Effective time management and prioritization skills.
  • Capability to lead cross-functional project teams and coach less experienced colleagues.
  • Ownership of design processes and participation in standards development.

Physical Demands:

This position requires regular communication and manual dexterity. The employee will frequently stand and walk, with occasional lifting of up to 25 pounds. The role involves significant computer-based work, necessitating periods of sitting and close vision.

Equal Opportunity Employer:

Generac is an equal opportunity employer. All qualified applicants will receive consideration for employment without regard to race, color, religion, sex, national origin, disability status, protected veteran status, or any other characteristic protected by law.

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