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Lead Automation Controls Engineer

2 months ago

Waukesha, Wisconsin, United States Generac Full time

About Generac:

At Generac, we are committed to enhancing safety, productivity, and innovation in the world. Our diverse team is driven by a shared mission to create positive change and deliver exceptional products and support to our global customers.

Position Overview:

We are currently seeking a Senior Controls Engineer to be part of our Advanced Manufacturing division at our Corporate Headquarters.

Key Responsibilities:

  • Design and implement automated and semi-automated control systems using sound engineering methodologies.
  • Develop PLC programming that interfaces with various subsystems, including conveyors, robotics, and machine vision systems.
  • Conduct research and development on emerging technologies to address complex automation challenges that directly affect product quality and delivery.
  • Assess legacy control systems for risks, formulate remediation strategies, and execute control upgrades accordingly.
  • Provide leadership and mentorship to automation suppliers and serve as a technical resource for engineering teams and project leaders.

Essential Duties:

  • Enhance processes through the application of both theoretical and practical engineering principles.
  • Establish factory-level and machine-level control standards for internal development teams and external partners.
  • Act as the corporate Subject Matter Expert (SME) for control systems programming, focusing on organized, maintainable, and reusable PLC code.
  • Implement safety systems compliant with ANSI/RIA15.06/OSHA standards for high-volume manufacturing equipment.
  • Create user-friendly HMI interfaces for complex machinery while ensuring effective troubleshooting feedback.
  • Collaborate with IT to integrate manufacturing assets into the enterprise network following established guidelines.
  • Stay updated on significant technical trends and incorporate relevant advancements into projects.
  • Manage requests for quotations and proposals, coordinating cross-functional reviews of machine requirements and engaging suppliers for design assessments.
  • Travel to supplier locations for equipment qualification and support during build events.
  • Occasional travel to other company sites for necessary support.

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, 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.
  • Proficient in creating technical specifications for automated manufacturing equipment and conducting failure analysis.
  • Strong knowledge of machine safety circuit design and safety PLC programming.
  • Familiarity with software and SCADA platforms supporting Industry 4.0 initiatives.
  • Experience with machine integration and common IoT platforms.
  • Proficiency in SQL and Python/Java is advantageous.
  • Effective communication skills in a global environment.
  • Prior experience with ERP systems such as SAP is a plus.
  • Experience with Fanuc robotics is beneficial.

Skills and Abilities:

  • Ability to work independently while seeking guidance on complex technical issues.
  • In-depth knowledge and expertise in relevant fields.
  • Utilizes best practices to enhance products and services.
  • Strong analytical problem-solving and decision-making skills.
  • Ability to lead cross-functional project teams and ensure collaborative success.
  • Actively mentors less experienced colleagues and contributes to standards development.

Physical Requirements:

This role requires regular communication and manual dexterity. The employee must be able to stand, walk, and occasionally lift up to 25 pounds. The position involves frequent computer-based work, necessitating periods of sitting and close vision.

Generac is an equal opportunity employer, and 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.