Senior Controls Engineer

Job Description

Job Description

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

Technical Qualifications 

• 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

Sales & Business Development 

• 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 Leadership 

• 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

Education and Experience 

• Professional degree in Electrical Engineering, Control Systems Engineering, Mechanical or Chemical Engineering, or a related field
• 6 to 12 years of experience minimum in automation and control system engineering with a focus on Emerson DeltaV

Work Conditions The physical demands and work-environment characteristics described here are representative of those an employee encounters while performing the essential functions of this job. Reasonable accommodation may be made to enable individuals with disabilities to perform the essential functions. The following requirements apply to implementing automation solutions at the customer location:

• Travel
  • 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)

• Physical Demands
  • 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 Environment 

• 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.

Our People 

• Empowered Employee-Owners – As owners of Wunderlich-Malec, we are invested in its success. We hire top talent and empower them to take initiative, drive innovation, and deliver impactful solutions
• Motivated & Rewarded – We invest in continuing education and offer world-class benefits, ensuring our employee-owners stay motivated, fulfilled, and future-ready
• Positive & Committed – Our experts bring long-term dedication and a positive, can-do attitude to every project
• Industry-Smart – Recognized leaders in their fields, our employee-owners stay sharp through ongoing training and deep knowledge of evolving industry trends

*Job Descriptions are not exhaustive lists of all skills, responsibilities, or efforts associated with a job.  They reflect principal job elements essential for performing the job and evaluating performance.

Wunderlich-Malec is proud to offer a comprehensive employee-owner benefit package. Full-time employees may be eligible for the following benefits:  Medical • Dental • Vision • Basic and Supplemental Life and AD&D • Long Term Disability • Voluntary Short Term Disability • Healthcare & Dependent Care Flexible Spending Accounts • Health Savings Account • Paid Time Off (PTO) • Paid Holidays • Tuition Reimbursement • Referral Bonus Program • 401(k)/Profit Sharing • 100% ESOP (Employee Stock Ownership Plan) • Employee Assistance Program • Will Preparation Resources • Worldwide Travel Assistance 

The salary range is $110,000 to $160,000 annually depending on qualifications plus a discretionary bonus and employee stock program.