Senior Controls Engineer Jobs in Madison, WI (NOW HIRING)

AprilAire continues to grow and our Advanced Engineering Team in Madison is no exception! They are currently looking to add a new Senior Auotmation Engineer to the fold. 

The Senior Automation Engineer will be responsible for executing the integration, commissioning, and stabilization of advanced automated manufacturing equipment, including robotic and vision-based systems. This role serves as a system-level integrator, ensuring mechanical, controls, and process elements function together to achieve safe, reliable, and production-ready performance.

The role contributes to the development and concepting of automation solutions by working across mechanical and controls disciplines to ensure designs are practical, integrated, and executable in a production environment. The Senior Automation Engineer supports projects from early design review through implementation and ramp-up, ensuring systems transition effectively from concept to stable production.

This is a hands-on execution role supporting critical capital equipment projects. The position focuses on system startup, debugging, and performance stabilization while working within established mechanical and control system standards.

This role is designed as a growth path into a Principal Automation Engineer position, with future expectations to take on increasing responsibility in robotics, vision systems, and system-level integration strategies.

This will be an onsite position that requires travel to both our Madison and Poynette facilities.

• Lead execution of equipment startup, commissioning, and ramp-up activities
• Perform I/O checkout, system bring-up, and sequence validation
• Debug system-level issues across PLC controls, mechanical systems, and process conditions
• Support integration and troubleshooting of robotic and vision systems
• Modify PLC and HMI logic to resolve issues and support functionality
• Assist with motion tuning and sequence optimization
• Diagnose and resolve electrical, mechanical, and controls issues
• Drive improvements in throughput, uptime, and quality during ramp
• Coordinate with internal teams and external vendors during execution phases
• Support documentation updates and system turnover to Production and Maintenance
• Strong understanding of automated manufacturing systems and machine integration
• Experience with PLC programming platforms (Rockwell, Mitsubishi preferred)
• Working knowledge of mechanical systems, fixturing, and equipment functionality
• Strong troubleshooting and root cause analysis capability
• Ability to diagnose issues across controls, mechanical, and process interactions
• Experience with robotics and vision systems with interest in developing expertise
• Ability to read and interpret electrical schematics and mechanical drawings

• Bachelor’s degree in manufacturing, mechanical, electrical, or controls engineering, or an equivalent combination of education and experience.
• 7+ years of experience in industrial automation, equipment integration, or controls engineering.
• Hands-on experience with equipment commissioning and production startup is required.
• Strong understanding of automated manufacturing systems and machine integration
• Experience with PLC programming platforms (Rockwell, Mitsubishi preferred)
• Working knowledge of mechanical systems, fixturing, and equipment functionality
• Strong troubleshooting and root cause analysis capability
• Ability to diagnose issues across controls, mechanical, and process interactions
• Experience with robotics and vision systems with interest in developing expertise
• Ability to read and interpret electrical schematics and mechanical drawings

• Bachelor’s degree in manufacturing, mechanical, electrical, or controls engineering, or an equivalent combination of education and experience.
• 7+ years of experience in industrial automation, equipment integration, or controls engineering.
• Hands-on experience with equipment commissioning and production startup is required.
• Strong understanding of automated manufacturing systems and machine integration
• Experience with PLC programming platforms (Rockwell, Mitsubishi preferred)
• Working knowledge of mechanical systems, fixturing, and equipment functionality
• Strong troubleshooting and root cause analysis capability
• Ability to diagnose issues across controls, mechanical, and process interactions
• Experience with robotics and vision systems with interest in developing expertise
• Ability to read and interpret electrical schematics and mechanical drawings