Staff Controls Engineer

About the role

Primary Purpose The Engineer IV – Controls (Staff Engineer) is responsible for providing expertise regarding new product development as well as continuous improvement of legacy systems. Day to day responsibilities include control design and tuning, simulation development, PLC programming, and electrical system integration. Additionally, candidates will facilitate product development through design, validation, and release.

Responsibilities

• Designs, validates, and brings new products to market.
• Specifies precise new product functional requirements; designs, tests and integrates a variety of increasingly complex components to produce final designs; and evaluates the design's overall effectiveness, cost (including cost/benefit analysis), reliability (risk analysis), and safety.
• Designs, develops, executes and evaluates fitness-for-use testing, product specifications and process validation plans for a variety of increasingly complex products and/or components; creates and reviews material part specifications and bills of materials.
• Collaborates with internal manufacturing partners, contract manufacturers, designers and product specialists to optimize increasingly complex designs for manufacturability.
• Utilizes PLC programming proficiency to develop programming instructions for optimal machine operation.
• Supports product development plans (schedule, product cost, meeting design inputs).
• Acts as a resource to mentor and teach less experienced engineers.
• Other duties as assigned.

Requirements

• Education: Bachelor of Science Degree in Electrical Engineering or related discipline.
• Experience: 7+ years of relevant work experience.
• Knowledge / Skills / Abilities: Designs, validates, and brings new products to market; specifies precise new product functional requirements; designs, tests and integrates a variety of increasingly complex components to produce final designs; evaluates design effectiveness, cost, reliability, and safety; designs, develops, executes and evaluates fitness-for-use testing, product specifications and process validation plans; creates and reviews material part specifications and bills of materials; collaborates with internal manufacturing partners, contract manufacturers, designers and product specialists to optimize designs for manufacturability; utilizes PLC programming proficiency to develop programming instructions for optimal machine operation; supports product development plans (schedule, product cost, meeting design inputs); acts as a resource to mentor and teach less experienced engineers.
• Physical Requirements and Working Conditions: Office Environment – regularly required to talk and hear, use hands to manipulate objects or controls, stand and walk; occasional stoop, bend, or reach above shoulders; occasional lift up to 25 pounds; frequent computer-based work requiring sitting, close vision, ability to adjust focus; occasional travel. Production Environment – regularly required to stand, frequently use hands to manipulate objects, tools, or controls, talk and hear; regularly walk, stoop, crouch, bend and reach above shoulders; frequently lift and/or move up to 50 pounds unassisted and up to 100 pounds with assistance, waist high, up to 10 feet away; vision abilities include close, distance, peripheral, depth perception; work in typical manufacturing conditions including seasonal temperature variations, occasional exposure to manufacturing fumes or byproducts; must comply with PPE requirements (safety glasses, hearing protection, appropriate gloves, clothing, shields, closed-toed or safety shoes); must be able to work in varying weather conditions including extreme heat, snow, and ice; may be required to obtain a DOT Medical Card and drive a heavy‑duty truck daily.

Qualifications

• Ability to perform detail‑oriented work with a high degree of accuracy on multiple projects of increasing complexity.
• Proven expertise in developing control algorithms across diverse power control and power management applications.
• Expertise in closed‑loop tuning, control tuning, stability analysis, and performance optimization of advanced control algorithms.
• Expertise in model‑based design methodologies, including development of high‑fidelity system simulations, automated design verification and production‑ready auto code generation.
• Experience in test & validation plan and procedure development and execution including multiple methods (HIL/SIL, bench component and/or system testing, fault injection methods, etc.).
• Experience in new product design and development.
• Active participant in technical communities tied to industry standards or regulations.
• Strong written communication and presentation skills; ability to translate technical information to all audiences.
• Applies engineering knowledge and experience to improve products, services and processes; able to solve complex engineering problems.
• Proficiency with MS Excel, MS Word.
• Experience with machine design.
• Previous experience with SAP or equivalent ERP.