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

Steele Solutions

Controls Engineer IV

Milwaukee, WI · On-site

$82K - $106K/yr

About the Role Under minimal supervision, the Controls Engineer IV is a senior technical role responsible for leading the development and deployment of highly complex control systems for large-scale ...

Steele Solutions

Controls Engineer I

Milwaukee, WI · On-site

$82K - $106K/yr

Seek feedback and support from senior engineers to build core competencies. * Follow established ... controls programming or automation systems (internships/co-ops acceptable). Other Key Skills

Aegis

Project Controls Engineer

Mount Pleasant, WI · On-site

$90K - $130K/yr

... trusted senior staff. With over two decades of experience solving the industry's toughest ... About the Role We seek a Project Controls Engineer to provide scheduling support services to our ...

Consultaegis

Project Controls Engineer

Mount Pleasant, WI · On-site

$90 - $130/hr

... trusted senior staff. With over two decades of experience solving the industry's toughest ... About the Role We seek a Project Controls Engineer to provide scheduling support services to our ...

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All JobsControls Engineer JobsSenior Controls Engineer JobsSenior Controls Engineer Jobs in Pewaukee, WI

Senior Controls Engineer information

See Pewaukee, WI salary details

$70.5K

$112.3K

$150.7K

How much do senior controls engineer jobs pay per year?

As of Aug 20, 2026, the average yearly pay for senior controls engineer in Pewaukee, WI is $112,263.00, according to ZipRecruiter salary data. Most workers in this role earn between $94,900.00 and $125,300.00 per year, depending on experience, location, and employer.

What is a senior controls engineer?

Senior Controls Engineers are experienced professionals who design, develop, and implement control systems for manufacturing processes, machinery, or automation equipment. They are responsible for programming controllers (such as PLCs), troubleshooting control system issues, and ensuring optimal system performance and safety. Senior Controls Engineers often lead project teams, mentor junior engineers, and collaborate with other departments to integrate new technologies. Their expertise is crucial for streamlining production, reducing downtime, and maintaining compliance with industry standards.

What are the typical responsibilities of a senior controls engineer in a manufacturing environment?

As a Senior Controls Engineer in a manufacturing setting, you can expect to lead the design, programming, and troubleshooting of automation systems such as PLCs, HMIs, and SCADA. Your responsibilities often include overseeing control system upgrades, optimizing equipment for efficiency, and ensuring compliance with safety standards. You will regularly collaborate with cross-functional teams—including maintenance, production, and IT—to implement solutions and support continuous improvement initiatives. Managing complex projects and mentoring junior engineers are also common aspects of the role.

What are the key skills and qualifications needed to thrive as a senior controls engineer?

To thrive as a Senior Controls Engineer, you need a strong background in electrical engineering, automation, and control systems, often supported by a relevant bachelor's degree and several years of experience in industrial automation. Expertise in PLC programming, SCADA systems, HMI development, and knowledge of industry standards and certifications like ISA or PE are typically required. Strong analytical thinking, project management, and excellent communication skills help distinguish top performers in this role. These competencies ensure the effective design, implementation, and troubleshooting of complex control systems, which are critical for operational safety, efficiency, and project success.

What is the difference between Senior Controls Engineer vs Controls Engineer?

AspectSenior Controls EngineerControls Engineer
Required CredentialsBachelor's degree in engineering, experience, possibly certifications like Certified Control Systems Technician (CCST)Bachelor's degree in engineering or related field, entry to mid-level experience
Work EnvironmentDesign, development, troubleshooting, project leadership in industrial or manufacturing settingsImplementing control systems, programming, testing, and maintenance in similar environments
Employer & Industry UsageManufacturing, automation, process control companiesSimilar industries, often as entry to mid-level roles within the same sectors

The main difference is experience level and responsibility. Senior Controls Engineers typically lead projects, design complex systems, and mentor junior staff, while Controls Engineers focus on implementing and maintaining control systems. Both roles require similar credentials and work in comparable environments, but the senior role involves more leadership and advanced technical skills.

What are the most commonly searched types of Controls Engineer jobs in Pewaukee, WI?

The most popular types of Controls Engineer jobs in Pewaukee, WI are:

What are popular job titles related to Senior Controls Engineer jobs in Pewaukee, WI?

For Senior Controls Engineer jobs in Pewaukee, WI, the most frequently searched job titles are:

What cities near Pewaukee, WI are hiring for Senior Controls Engineer jobs?

Cities near Pewaukee, WI with the most Senior Controls Engineer job openings:

Senior Controls Engineer jobs near you
Infographic showing various Senior Controls Engineer job openings in Pewaukee, WI as of August 2026, with employment types broken down into 90% Full Time, 7% Part Time, and 3% Contract. Highlights an 85% Physical, 6% Hybrid, and 9% Remote job distribution, with an average salary of $112,263 per year, or $54 per hour.

Principal Controls Engineer (Team Lead)

STELLA & CHEWY'S LLC

Oak Creek, WI • On-site

$79K - $103K/yr

Full-time

Re-posted 2 hours ago

Job description

Description

ABOUT STELLA & CHEWY'S

At Stella & Chewy's, we believe pets deserve food as close to nature as possible - and that belief drives everything we do. From raw frozen dinners to freeze-dried treats, our products are crafted with purpose and made with real ingredients pets love. We're a mission-driven company with big growth ambitions, and we're building the team that will take us there.


THE OPPORTUNITY

The Principal Controls Engineer is the senior technical leader of the controls department, responsible for the strategy, design, implementation, and continuous improvement of all automation and controls systems across the facility. This individual serves as the highest-level controls subject matter expert, directly manages the Controls Engineer, and provides technical direction and mentorship to the Controls Technician via a dotted-line relationship.

This is a hands-on leadership role. The Principal Controls Engineer is expected to balance high-level project ownership with direct technical contribution - reviewing and approving controls designs, driving capital projects, establishing best practices and standards, and supporting manufacturing operations as the senior escalation resource for complex controls issues.

The Principal Controls Engineer reports directly to the Director of Engineering and holds full supervisory responsibility for the Controls Engineer. The Controls Technician reports on a solid line to the Maintenance Supervisor and on a dotted line to the Principal Controls Engineer for technical direction, work prioritization on controls tasks, and professional development.


WHAT YOU'LL OWN


Technical Leadership & Standards

  • Establish and maintain controls engineering standards, including PLC/HMI programming conventions, network architecture, panel design standards, and documentation requirements.
  • Serve as the technical authority for all controls-related decisions, including platform selection, system architecture, and change management.
  • Lead root cause analysis and corrective action for complex or recurring controls-related failures.
  • Ensure all controls systems are designed and maintained to applicable electrical codes, NFPA 70E, and industry safety standards.

People Leadership

  • Directly supervise the Controls Engineer, including goal-setting, performance reviews, and professional development planning.
  • Provide technical direction, mentorship, and skill development to the Controls Technician via a dotted-line relationship, in coordination with the Maintenance Supervisor.
  • Build and sustain a high-performing controls team; support recruiting and onboarding as the department grows.

Capital Projects & Engineering

  • Lead or co-lead controls scope for capital projects from concept through commissioning, including scope definition, vendor selection, design review, FAT/SAT, and startup support.
  • Develop and maintain controls engineering project documentation: P&IDs, loop diagrams, I/O lists, control narratives, and as-built drawings.
  • Evaluate, select, and manage controls system vendors and integrators.
  • Champion automation opportunities to improve OEE, reduce manual labor, and enhance product quality.

Operations Support & Reliability

  • Serve as the senior technical escalation point for controls issues affecting production; available for critical off-hours support on major failures.
  • Create controls preventive maintenance program, including PLC backup schedules, drive calibrations, and instrument calibration intervals.
  • Maintain and continuously improve the controls system documentation library, including program archives, network diagrams, and spare parts inventory.
  • Partner with Production, Maintenance, and Quality to identify and resolve controls-related reliability and quality issues.
  • Develop and deliver electrical troubleshooting training for Maintenance Technicians spanning basic electrical fundamentals (voltage verification, motor checks, continuity and insulation/short-to-ground testing) through advanced controls diagnostics (PLC I/O faults, drive diagnostics, and controls panel troubleshooting); build skills within the broader maintenance team to reduce dependency on controls specialists for routine electrical issues.

Compliance & Safety

  • Ensure controls designs and modifications comply with applicable codes including NFPA 70, NFPA 79, and applicable machine safety standards (ISO 13849/IEC 62061).
  • Support site safety programs including LOTO, arc flash analysis, and electrical safety training for controls personnel.
  • Maintain accurate as-built documentation and control panel labels consistent with NFPA 79 requirements.


Requirements

WHAT YOU BRING

  • Bachelor of Science in Electrical Engineering, Controls Engineering, or a closely related engineering discipline.
  • 8+ years of progressive controls engineering experience in a manufacturing environment.
  • Advanced proficiency in PLC programming (Allen-Bradley ControlLogix / CompactLogix preferred; Siemens, Omron, or equivalent considered).
  • Strong experience with HMI/SCADA development (FactoryTalk View, Ignition, or equivalent).
  • Working knowledge of industrial networking: EtherNet/IP, DeviceNet, Profibus, Modbus.
  • Experience leading controls scope on capital projects, including vendor management and commissioning.
  • Demonstrated ability to lead and develop technical staff.
  • Proficiency with controls documentation tools (AutoCAD Electrical, EPLAN, or equivalent).

Preferred

  • Certified Automation Professional (CAP) or equivalent industry certification.
  • Familiarity with food & beverage or process manufacturing environments.
  • Experience with MES, OEE platforms, or historian systems (OSIsoft PI, Ignition Perspective).
  • Six Sigma, Lean Manufacturing, or formal reliability engineering (RCM/FMEA) background.


Core Competencies

  • Technical Depth & Breadth - Commands a wide range of controls disciplines and can translate complex technical problems into clear solutions.
  • Leadership & Coaching - Grows the capability of direct reports and dotted-line reports through clear expectations, feedback, and mentorship.
  • Project Execution - Manages multiple concurrent priorities, meets commitments, and communicates proactively on risks and schedule.
  • Collaboration - Works effectively across Maintenance, Production, Engineering, and Quality to drive aligned outcomes.
  • Continuous Improvement Mindset - Identifies opportunities to improve reliability, efficiency, and safety and drives them through to completion.
  • Communication - Communicates technical content clearly to both technical and non-technical audiences; documents work to a professional standard.




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