Project Control Engineer

Job Description

Controls Project Engineer (Direct Hire)

Location: Milwaukee, WI

Department: Engineering / Controls Engineering

Reports To: Controls Engineering Manager

Position Overview

The Controls Project Engineer is responsible for the control system performance and profitability of the related technical aspects of assigned projects, including electrical, safety, pneumatics, hydraulics, water, welding, lubrication, and programming.

This position requires a high level of collaboration and teamwork with internal and external stakeholders, including the Controls Engineering Manager, Controls Engineering, Project Management, Mechanical Engineering, Application Engineering, Sales, Assembly, Service, Purchasing, Shipping/Receiving, Human Resources, outside equipment builders, outside engineering firms, vendors/suppliers, and customers.

Systems may include programmable logic controllers (PLC), human machine interfaces (HMI), safety controllers, robots, servos, distributed I/O, welders, variable frequency drives, vision systems, material handling equipment, conveyors, spraying and dispensing systems, industrial networks, instrumentation, pneumatics, hydraulics, and electro-mechanical control devices.

Key Responsibilities

1. Controls Engineering & System Design

• Perform and champion controls-related engineering tasks, including conceptualization, risk assessment, design, generation of schematics, component specification, safety evaluation, purchasing support, programming, assembly support, debugging, safety validation, and field commissioning.
• Take responsibility for control system performance and profitability across the technical aspects of assigned projects, including electrical, safety, pneumatics, hydraulics, water, welding, lubrication, and programming.
• Employ continuous improvement methodologies to enhance controls designs and programming standards within a team environment.

2. Project Planning & Execution

• Participate in progress review and planning meetings with the Controls Engineering Manager, Project Manager, Mechanical Engineers, Assembly, and Service personnel throughout the design, build, start-up, commissioning, and warranty periods.
• Identify potential risk areas, long-lead items, and financial impacts early in the project to develop proactive or alternative solutions.
• Coordinate efforts with vendors, suppliers, outside engineering firms, and contract engineers on assigned projects.

3. Technical Leadership & Collaboration

• Provide leadership, guidance, assistance, technical mentoring, and hands-on support to internal and external controls engineers, assembly teams, and service staff.
• Collaborate with cross-functional teams and external partners to support successful project execution.
• Promote teamwork and continuous improvement in controls engineering practices.

Required Work Experience & Technical Qualifications

1. Professional Experience

• Minimum of eight (8) years of experience in custom automated equipment controls design, programming, debugging, troubleshooting, and support.
• Direct experience with assembly equipment is preferred, particularly in manufacturing and factory-floor automation.
• Strong CAD skills related to controls schematic generation:
• AutoCAD – Required
• AutoCAD Electrical or EPLAN – Plus

2. Control System Design Experience

Electrical Systems – Strong Experience Required

• Electrical component specification and sizing
• Power distribution and load calculations
• Short-Circuit Current Rating (SCCR) calculations
• Safety circuitry
• Electrical panel layouts and heat calculations
• Local and distributed I/O
• Sensors, variable frequency drives (VFDs), and servos
• System interfacing
• Industrial networks, including:
• Ethernet
• Ethernet/IP
• CIP Safety
• PROFINET
• PROFIsafe
• IO-Link

Pneumatic Systems – Some Experience Required

• Component specification and sizing
• Air preparation systems
• Safe exhaust systems
• Directional control valves
• Flow controls
• Pressure regulation
• Check valves

Safety Systems – Some Experience Required

• Safe distance calculations
• Safety categories and performance levels
• Risk assessments
• Safety circuit evaluation (SISTEMA)
• Safety system validation

Additional Control System Knowledge – Preferred / Plus

• Hydraulic Systems: Working knowledge is a plus.
• Welding Systems: Working knowledge of MIG, TIG, laser, resistance, and plasma welding is a plus.
• Lubrication Systems: Working knowledge is a plus.
• Robotics: Working knowledge is a plus.
• Peripheral Equipment: Working knowledge of RFID, laser etching, pin stampers, vision systems, barcode readers, serial interfaces, laser measurement, leak testers, and related systems is a plus.

3. Programming & Commissioning Experience

Programmable Logic Controllers (PLC) – Strong Experience Required

• Allen-Bradley preferred
• Siemens is a plus

Human Machine Interfaces (HMI) – Strong Experience Required

• Allen-Bradley preferred
• Siemens is a plus

Industrial Networks – Strong Experience Required

• Ethernet
• Ethernet/IP
• CIP preferred
• PROFINET or PROFIsafe is a plus

Programming Languages – Strong Experience Required

• Ladder Logic preferred
• Additional languages considered a plus:
• Structured Text
• Function Block
• Sequential Function Chart
• Graph
• Visual Basic
• Statement List
• Python

Programmable Safety – Some Experience Required

• Allen-Bradley preferred
• Siemens is a plus

Servo Systems – Some Experience Required

• Allen-Bradley preferred
• Siemens is a plus

Variable Frequency Drives (VFD) – Some Experience Required

• Allen-Bradley preferred
• Siemens is a plus

Robotics Interface – Some Experience Required

• FANUC or Yaskawa/Motoman preferred
• ABB or KUKA is a plus

Peripheral Systems – Some Experience Required

• RFID
• Laser marking
• Pin stampers
• Barcode readers
• Serial interfaces
• Measurement systems
• Leak testers

Additional Programming & Commissioning Knowledge – Preferred / Plus

• Machine Vision: Working knowledge is a plus; Keyence, Cognex, DataLogic, and/or IR Vision preferred.
• SCADA/MES Systems: Working knowledge is a plus.

4. Software & Computer Skills

Microsoft Office – Required

• Outlook
• Word
• Excel
• Project
• Other Microsoft Office applications

Database Experience – Plus

• Excel
• Access
• SQL
• Other database systems

Project Management & Leadership Requirements

• Proven experience managing project budgets and meeting project milestones is required.
• Experience as a Lead Controls Engineer, coordinating the efforts of multiple engineers on a given project, is required.
• Direct experience working with customers and suppliers is required.
• Experience providing designs that comply with industry-accepted standards and engineering practices.
• Ability to adapt to project-related design practices and programming standards.
• Familiarity with current and emerging technologies.

Professional & Interpersonal Skills

Candidates must demonstrate strong cross-functional communication and collaboration skills, including:

• Professional demeanor
• Cooperative personality
• Strong organizational skills
• Multitasking capabilities
• Team-oriented approach

Education Requirements

• Bachelor of Science in Electrical Engineering or a similar degree preferred.
• Related professional experience may be considered in place of the preferred degree.

Summary of Core Qualifications

The position requires a Controls Project Engineer with:

• A minimum of 8 years of custom automated equipment controls engineering experience.
• Strong electrical controls design and AutoCAD schematic generation skills.
• Strong PLC, HMI, industrial networking, and programming experience.
• Experience with pneumatic systems, safety systems, programmable safety, servos, VFDs, robotics interfaces, and peripheral equipment.
• Proven experience leading multiple controls engineers on projects.
• Demonstrated responsibility for project budgets and milestones.
• Direct customer and supplier interaction experience.
• Strong cross-functional communication, technical leadership, and collaboration skills.

A background in manufacturing and factory-floor automation, particularly custom assembly equipment, is preferred.