Senior Controls Engineer

We are Generac, a leading energy technology company committed to powering a smarter world.

Over the 60 plus years of Generac’s history, we’ve been dedicated to energy innovation. From creating the home standby generator market category, to our current evolution into an energy technology solutions company, we continue to push new boundaries.

Generac is seeking a Senior Controls Engineer to join our Advanced Manufacturing team at our Corporate HQ in Waukesha, WI!
In this role you will be responsible for design, implementation and successfully scale automated and semi- automated controls systems utilizing sound engineering principles and technologies.
Develop PLC code that will interact with subsystems such as conveyors, robots, Manufacturing Execution System MES, machine vision, and 3rd party equipment.
Perform the research and development on new technologies necessary to tackle complex assembly and automation problems that have direct impact to the quality and delivery of Generac products.
Identify legacy controls by risk assessment, create remediation plan, and execute controls upgrade according to plan.
Use your leadership skills for direction and mentorship of machine/automation suppliers; be the driver on internal projects; serve as a technical resource to other engineering groups and project leaders, while driving standards and process improvements.

Essential Duties & Responsibilities:

• Develop new and or improved processes through the application of theoretical and practical engineering

• Design and build out factory level, and line/machine level controls standards and specification for application by internal equipment development team and external partners

• Acts as the corporate SME for plant resources on control systems programing by architecting, writing and debug PLC ladder logic/IPC SW with an emphasis on generating code that is organized, structured, documented, maintainable and reusable. PLC code will interact with subsystems such as conveyors, robots, Manufacturing Execution System MES, machine vision, part tracking systems, and 3rd party equipment.

• Implement (ANSI/ RIA15.06/OSHA compliant) control reliable safety systems for safeguarding robots, gantries, conveyors, and other high volume manufacturing equipment

• Generate aesthetically simple HMI screens for complex machinery while providing sufficient feedback for troubleshooting

• Work with IT to connect manufacturing assets to enterprise network using established standards / guidelines

• Keeps abreast of all meaningful technical trends and developments and incorporates them in appropriate assignments

• Create request for Quotation/Proposal (RFQ/RFPs), Organize cross-functional reviews of the machine requirements, design, qualification and capability and engage machine suppliers for automated equipment design reviews and proposals

• Travel to the machine suppliers for equipment qualification, acceptance testing and support during build events

• Frequent travel to other Generac sites for support as needed. (Generally day trips)

Minimum Qualifications:

• Bachelor of Science Degree in Engineering, Computer Science, or related discipline

• 7+ years of experience with Rockwell Logix

Preferred Qualifications:

• Expert-level experience in design, program, integration, and validation of controls in high volume automated process equipment for discrete manufacturing using Rockwell Logix and GE RXi platforms.

• Experience in designing controls hardware and OT infrastructures including a thorough understanding of Industrial Communication Protocols

• Experience in creating technical specifications for automated manufacturing equipment, machine qualification requirements, design of experiments and failure analysis

• Expertise in the design of machine safety circuits and programming of safety PLCs

• Expertise with software and SCADA platforms to support Industry 4.0 manufacturing projects: including Historians and OPC Servers.

• Experience with machine integration with common IoT platforms

• Experience with SQL and Python/Java would be a plus.

• Able to communicate effectively in a worldwide environment.

• Previous experience with SAP or equivalent ERP.

• Experience with Fanuc robotics a plus.

Knowledge, Skills, & Abilities:

• Works independently, with occasional guidance on challenging technical issues;

• Requires in-depth knowledge and/or breadth of expertise;

• Uses best practices and knowledge of internal and external business issues to improve products or services;

• Recommends solutions and best practices;

• Strong conceptualization, visualization, and creativity;

• Strong time management, prioritization, and analytical problem solving;

• Solves complex problems;

• Takes a new perspective using existing solutions;

• Strong decision-making skills;

• Represents the level at which career may stabilize for many years or even until retirement;

• Progression to this level is typically restricted on the basis of business requirement;

• May lead cross-functional project teams;

• Ensures success cross-functionally;

• Actively coaches colleagues with less experience;

• Offer recommendations and implement solutions;

• Take ownership of designs;

• Participates in standards and procedure development;

• Leading efforts to improve the financial impact of engineering activities on the businesses and thorough understanding of how other functions impact the business;

Physical Demands: While performing the duties of this job, the employee is regularly required to talk and hear; and use hands to manipulate objects or controls. The employee is regularly required to stand and walk.  On occasion the incumbent may be required to stoop, bend or reach above the shoulders. The employee must occasionally lift up to 25 - 50 pounds. Specific conditions of this job are typical of frequent and continuous computer-based work requiring periods of sitting, close vision and ability to adjust focus. Occasional travel.

“We are an equal opportunity employer and all qualified applicants will receive consideration for employment without regard to race, color, religion, sex, sexual orientation, national origin, disability status, protected veteran status, or any other characteristic protected by law.”