Job Description

Job Title: Senior Controls/Test Engineer

Location: 2300 Badger Drive, Waukesha, WI, 53188, USA

Core Hours: 7:00 AM – 3:00 PM (may require early/late work for projects)

Interview Process:

• Phone/Virtual Screening
• Panel Interview & On-site Tour (same day)

Position Overview

The Senior Controls/Test Engineer plays a critical role in supporting plant leadership to achieve business and financial goals by developing and maintaining robust testing and assembly processes. This individual will lead the design, development, validation, installation, and troubleshooting of production test equipment and programs while serving as a coach and mentor to junior engineers and technicians.

Key Responsibilities

• Establish guidelines for the design, selection, and implementation of test equipment, testing protocols, and data collection programs.
• Troubleshoot, service, and support test equipment and electrical systems within the plant.
• Develop test equipment specifications ensuring compliance with OSHA, NFPA 70E, and electrical safe work practices.
• Identify and remediate safety hazards; enforce a zero-incident culture.
• Collaborate cross-functionally with manufacturing, engineering, quality, suppliers, and customers.
• Conduct root cause and failure analysis; apply structured problem-solving methodologies and mentor others in these practices.
• Guide capital equipment selection and prepare/evaluate Capital Appropriation Requests (CARs).
• Drive cost-out initiatives and continuous improvement using Lean and Six Sigma tools.
• Lead or co-lead Kaizens/BPIs and support facility-wide assessment processes.
• Implement advanced technologies to improve information systems for testing and controls.
• Manage projects, budgets, goals, and stakeholder communications.
• Lead change management initiatives using ADKAR and MOC (Management of Change) processes.

Basic Qualifications

• Bachelor’s Degree in Engineering, Computer Science, Mathematics, or related field from an accredited institution.
• Minimum 3 years of controls/test engineering experience.
• Strong programming experience with software such as Visual Basic/Studio, SQL, Microsoft applications, and industrial automation platforms:
• Rockwell Software (RSLogix 5, RSLogix 500, RSLogix 5000, Studio 5000, FactoryTalk View ME/SE, VB6)
• NI LabVIEW and NI TestStand
• Hands-on experience with PLCs, HMI programming, and safety system design.
• Project management experience.
• Must be legally authorized to work in the U.S. without company sponsorship.

Preferred Qualifications

• 5+ years of Controls/Test Engineering experience.
• Green Belt (GB) or Black Belt (BB) certification in Lean Six Sigma.
• Strong understanding of structured problem-solving methodologies (8D, A3, FMEA, Pareto, Control Charts, etc.).
• Experience in electrical testing procedures and protocols.
• Deep knowledge of electrical equipment at component and system levels.
• Proficiency in interpreting and troubleshooting electrical schematics, instrumentation, protection, and metering diagrams.
• Familiarity with Engineered-to-Order (ETO) manufacturing environments.
• Experience with PROLaunch or similar project management methodologies.
• Demonstrated ability to lead cross-functional teams and work independently.
• Strong skills in guiding contractors through equipment installation and troubleshooting.

📩 Please reach out at [email protected] or call 520-366-3115 .

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