Controls Engineer in New Berlin
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Job DescriptionJob DescriptionResponsibilities
Develop, implement, and administer the plant’s Allen-Bradley controls and Ethernet/IP network (Hirschmann, Stratix, managed switches).Engineer and deliver reliable automation solutions including PLC logic, PowerFlex drive integration, device selection, electrical panel design, flow charts, scopes of work, schedules, and cost estimates—either in-house or with integrators.Provide advanced break/fix support for all automation, controls, PLC, VFD, HMI, and network-related issues.Serve as the subject matter expert for Allen-Bradley automation—including ControlLogix, CompactLogix, PanelView, and FactoryTalk systems.Troubleshoot complex automation, electrical, and network problems across the entire plant.Produce energy, production, and operational reports using Wonderware Historian, ICIS Energy Management, ICIS Plant Performance, SEEQ, etc.Administer, maintain, and update all plant databases, historians, and automation data structures.Maintain and manage all automation-related programs and documentation including:PLC programs (AB ControlLogix/CompactLogix)HMI programs (FactoryTalk View ME/SE, Ignition, Wonderware)Electrical ladder diagrams, P&IDs, pin charts, and sequences of operationMaintain and update all controls/automation software for the facility: Rockwell Studio 5000, FactoryTalk, PowerFlex tools, Ignition, Wonderware, ICIS, network monitoring tools, etc.Partner with internal teams to develop and implement best practices for the facility and for corporate locations.Support cross-functional engineering and maintenance teams with automation expertise and project execution.Work closely with IT to bridge plant-floor data with ERP/MES systems.Continuously evaluate and implement industry best practices for controls, networking, data, and automation reliability.Share technical knowledge with plant teams and provide training on controls, VFDs, PLC troubleshooting, and best practices.Requirements
5+ years as a Controls/Automation Engineer (Allen-Bradley focused).Electrical Engineering degree OR 10+ years relevant experience .Advanced experience with Allen-Bradley PLCs (ControlLogix, CompactLogix, ladder logic, function block, tag-based programming).Advanced experience with PowerFlex drives (setup, tuning, Ethernet/IP comms, troubleshooting).Advanced experience with HMIs (FactoryTalk View ME/SE, Ignition, Wonderware).Strong experience with Wonderware Historian, SEEQ, and ICIS reporting tools.Strong knowledge of Ethernet/IP networks, industrial switches, and Hirschmann/HiVision.Advanced capability in electrical control design and industrial automation hardware selection.Broad experience with automation devices: sensors, servos, safety circuits, VFDs, I/O, instrumentation, and industrial communications.Intermediate proficiency with Windows OS, PCs, virtual machines (VMWare/Hyper-V).Intermediate experience with MSSQL, Microsoft Access, and OPC interfaces.Ability to create electrical diagrams, flow diagrams, and P&IDs using AutoCAD and Visio.Strong team-oriented mindset with the ability to train others and communicate technical concepts clearly.Strong documentation skills and the ability to manage multiple technical tasks under time constraints
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