Senior Controls Engineer

About the role

Wunderlich-Malec Engineering (WM) is a 100% employee-owned ESOP and one of the largest and most well-established engineering companies in the United States, with 40+ years of industry history, recognized as an ENR Top 500 firm and a top System Integrator Giant. This Senior Controls Engineer position in Philadelphia, PA involves designing and implementing advanced Emerson DeltaV and/or Rockwell automation solutions for the Life Sciences industry, delivering high-quality, fit-for-purpose, regulatory-compliant automation that supports biopharmaceutical and small molecule API manufacturing.

Responsibilities

• Develop, configure, and implement Emerson DeltaV control systems aligned with customer specifications, 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 life sciences clients 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
• Conduct Factory Acceptance Testing (FAT) and Site Acceptance Testing (SAT) to validate system performance
• Perform instrument specification, wiring, troubleshooting, and calibration
• Develop and/or redline control drawings and electrical schematics detailing control system configuration, major hardware and wiring, and control panel layouts; provide work direction to technicians creating drawings
• Provide on-site startup, commissioning, and troubleshooting support for deployed systems in production environments
• Ensure compliance with system and software development life cycle methodologies, including validation documentation
• Work closely with multidisciplinary teams (electrical, process, validation engineers, 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 (biotechnology, pharmaceuticals, medical devices) preferred
• 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 ability to diagnose and resolve complex automation issues
• Ability to translate 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

Sales & Business Development

• Participates in proposals and writes sections of proposals as directed
• 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

• 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)
• 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; 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
• Frequent reaching, bending, stooping, crouching, or crawling in and around machinery and production equipment during project commissioning and startup
• Manual dexterity sufficient to operate tools, instruments, or computer equipment
• Ability to wear required personal protective equipment (PPE) such as safety glasses, gloves, hard hats, and steel-toed boots
• Visual acuity, color vision, 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, equipment on a ladder, and light electrical assembly (e.g., signal wiring in control panels/instruments)
• Construction trailer and Data Center environment with frequent PC and cell phone usage
• Typical PPE required: safety glasses, steel-toed shoes, hearing protection, and electrical safety PPE; employees must comply with customer-specific requirements

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

Pay

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