Controls Test Engineer

Equiliem
United States, Wisconsin, Waukesha
Sep 28, 2025
Job Summary The Senior Controls/Test Engineer supports plant leadership in achieving business and operational goals by developing, implementing, and maintaining robust test and assembly processes. This position is responsible for the design, development, validation, and troubleshooting of production test equipment and control systems. The Senior Controls/Test Engineer provides technical leadership, mentors other engineers, and drives continuous improvement initiatives to enhance product quality, safety, and efficiency. Job Responsibilities Design, develop, and implement test equipment specifications, testing protocols, and data collection systems in compliance with electrical safety and OSHA requirements Support, service, and troubleshoot test equipment and electrical systems within the manufacturing facility Identify and mitigate safety hazards, ensuring equipment functionality meets performance and safety standards Partner with cross-functional teams, including Manufacturing, Quality, Product Design Engineering, EHS, and suppliers, to support operational and project goals Perform root cause and failure analyses, applying structured problem-solving methodologies and mentoring others in these techniques Lead or support capital equipment selection and development, including Capital Appropriation Requests (CARs) for new projects or initiatives Participate in manufacturing assessments, serving as a category lead or subject matter expert when required Drive cost-reduction and continuous improvement initiatives using Lean and Six Sigma methodologies; track and report associated metrics Lead and manage projects by defining objectives, budgets, and timelines while aligning resources across departments to achieve project milestones Leverage advanced technologies and digital tools to improve test and control system performance and data accuracy Develop and execute change management strategies using structured approaches such as ADKAR and Management of Change (MOC) processes to sustain operational improvements Promote and enforce a culture of electrical safety, compliance, and zero incidents across all test and control system operations Job Requirements Bachelor's degree in Engineering, Computer Science, Mathematics, or a related technical discipline from an accredited institution Minimum of 3 years of experience in test or controls engineering Proficiency in PLC and HMI programming, safety system design, and automation controls Experience with Rockwell Software (RSLogix 5, RSLogix 500, RSLogix 5000, Studio 5000, FactoryTalk View ME/SE, VB6) Experience with NI LabVIEW, NI TestStand, and Visual Basic/Studio; familiarity with SQL and Microsoft applications Strong understanding of electrical systems, instrumentation, and test methodologies Proven ability to manage multiple projects and collaborate effectively in cross-functional teams Legally authorized to work in the U.S. without company sponsorship Preferred Qualifications 5+ years of experience in controls and test engineering Green Belt (GB) or Black Belt (BB) certification in Lean Six Sigma Experience applying structured problem-solving methodologies such as 8D, root cause analysis, FMEA, control charts, or Pareto analysis Knowledge of electrical testing procedures, equipment design, and integrated system functionality Experience implementing Electrical Safe Work practices per NFPA 70E Experience troubleshooting electrical control, protection, instrumentation, and metering systems Background in Engineered-to-Order (ETO) manufacturing environments Familiarity with PROLaunch or other project management frameworks Demonstrated ability to work independently while supporting collaborative team environments Additional Job Details Full-time, on-site position in a manufacturing environment May require occasional overtime or off-shift work to support production schedules