Senior Controls Engineer

About Us:

Machine Solutions is the premier provider of advanced equipment and services for the medical device, biopharmaceutical, and blood- and plasma-collection industries. We support our customers’ needs and growth by delivering quality and value through a wide breadth of products. Machine Solutions provides proprietary mechanical solutions to a variety of complex process, testing and device design challenges. Our equipment has become the industry standard for stent crimping, balloon catheter pleating and folding, catheter braiding and medical device manufacturing applications. As a pioneer in radio frequency technology, the company has continued to develop advancing technology for thermal forming, molding and welding plastic for medical manufacturing, biopharmaceutical, and blood- and plasma-processing applications. Our experienced team of engineers has been instrumental in automating manual processes that enable our customers to increase production volumes and profit margins, and we believe in providing a superior customer experience by designating resources to a dedicated aftermarket team that is always ready to provide technical service and process support. Machine Solutions is privately owned by BW Forsyth Partners, a Barry-Wehmiller company.BW Forsyth Partners is the investment arm of multibillion-dollar global manufacturing and engineering consulting firm Barry-Wehmiller. Established in 2009, BW Forsyth Partners blends Barry-Wehmiller’s unparalleled legacy of value creation and people-centric culture development with keen investing experience to help companies realize their true potential. With a focus limited to areas known well, BW Forsyth Partners seeks to partner with leadership teams to acquire small- to middle-market companies in the capital and component equipment, and professional services sectors. In each of our operating companies, BW Forsyth Partners deploys operational improvements and strategy development without compromising the autonomy, strategic vision and entrepreneurial spirit of their leadership teams.

Job Description:

SENIOR CONTROLS ENGINEER

JOB OVERVIEW:

Senior Controls Engineer’s role designs, modifies, develops, writes and implements all aspects of electrical controls systems software and hardware relevant to equipment used for the processing of implantable medical devices. This role will have a broad scope of responsibility from creating electrical and pneumatic, to developing software and executing software test plans, writing test reports and system level troubleshooting.

ESSENTIAL DUTIES AND RESPONSIBILITIES:

• Serves as a subject matter expert in electrical systems and control software.
• Supports cross-functional teams in the design, development, and validation of new products.
• Identifies opportunities for innovation and process improvements that enhance quality, efficiency, and cost-effectiveness.
• Collaborates with other engineering disciplines to ensure seamless integration of electrical, mechanical, and software components.
• Interfaces directly with customers to identify customer expectations and specifications.
• Interfaces with suppliers to select and develop the best available technical solutions.
• Participates in the development of strategic plans and road maps for the electrical engineering function.
• Demonstrates exceptional problem-solving, leadership, and communication skills.
• Reviews existing products suggests improvements and implements changes to reduce costs and improve quality.
• Demonstrates a deeper understanding of electrical, software, mechanical, hydraulic, and pneumatic systems and components.
• Demonstrates an advanced knowledge of Omron, AB, Beckhoff, and C# software development from scratch.
• Mentors and develops team members, providing guidance on complex technical challenges.
• Responsible for leading small to medium sized projects or initiatives.
• Ad-hoc projects as needed

QUALIFICATIONS:

To perform this job successfully, an individual must be able to perform each essential duty satisfactorily. The requirements listed below are representative of the knowledge, skill, and/or ability required. Reasonable accommodations may be made to enable individuals with disabilities to perform the essential functions.

The Senior Controls Engineer must be able to perform the duties of a Controls Engineer II satisfactorily.

EDUCATION AND/OR EXPERIENCE:

• Bachelor's degree in electrical engineering or relevant degree preferred
• 5-7 years of professional experience in a related role

KNOWLEDGE, SKILLS, AND ABILITIES:  

• Advanced expertise in Omron, Allen-Bradley (AB), and Beckhoff automation systems, including PLC programming, HMI development, and integration with custom C# software applications built from the ground up.
• In-depth understanding of electrical, software, mechanical, hydraulic, and pneumatic systems, with the ability to troubleshoot and optimize complex multidisciplinary systems.
• Proven ability to identify and implement innovative solutions and process improvements to enhance product quality, increase operational efficiency, and reduce costs.
• Strong ability to interface directly with customers to understand and translate their expectations and specifications into actionable project requirements.

CONTROLS ENGINEER II

JOB OVERVIEW:

The Controls Engineer II’s role designs, modifies, develops, writes and implements all aspects of electrical controls systems software and hardware relevant to equipment used for the processing of implantable medical devices. This role will have a broad scope of responsibility from creating electrical and pneumatic, to developing software and executing software test plans, writing test reports and system level troubleshooting. Plays a key role in product validation, overseeing testing procedures and communicating with external laboratories.

ESSENTIAL DUTIES AND RESPONSIBILITIES:

• Supports testing done by internal and external laboratories. Communicates with independent testing companies when certifications are required.
• Troubleshoots circuits and writes/debugs control system software.
• Demonstrates a basic knowledge of Omron, AB, Beckhoff, and C# software development using existing code.
• Prepares schematics, assemblies, detailed drawings and bills of material for moderately complex projects.
• Furnishes documentation to product assembly and assist with check-out, machine installation and startup of moderately complex mechanical functionality and control system software.
• Demonstrates a deeper understanding of electrical, software, mechanical, hydraulic, and pneumatic systems and components.
• Evaluates and implements improvements to production methods and processes.
• Supports small-to-medium-sized projects or initiatives.
• Demonstrates the proper usage of GMPs and quality procedures.
• Investigates customer complaints and executes resolution to problems.
• Must be able to travel if there is a need but no more than 10%.
• Ad-hoc projects as needed

QUALIFICATIONS:

To perform this job successfully, an individual must be able to perform each essential duty satisfactorily. The requirements listed below are representative of the knowledge, skill, and/or ability required. Reasonable accommodations may be made to enable individuals with disabilities to perform the essential functions.

Controls Engineer II must be able to perform the duties of a Controls Engineer I satisfactorily.

EDUCATION AND/OR EXPERIENCE:

• Bachelor's degree in electrical engineering or relevant degree preferred
• 3-5 years of professional experience in a related role

KNOWLEDGE, SKILLS, AND ABILITIES:   

• Proficiency in Omron, Allen-Bradley (AB), and Beckhoff automation systems, including foundational PLC programming and HMI development.
• Strong understanding of electrical, software, mechanical, hydraulic, and pneumatic systems, with the ability to assist in troubleshooting and optimizing control systems.
• Ability to contribute to process improvements and efficiency enhancements under supervision.
• Experience working with customers to gather project requirements and translate them into technical tasks.
• Ability to independently troubleshoot circuits and write/debug control system software.

• Demonstrates a deeper understanding of electrical, software, mechanical, hydraulic, and pneumatic systems and components.

CONTROLS ENGINEER I

JOB OVERVIEW:

The Control Engineer I’s role tests and repairs electrical/electronic, mechanical, hydraulic, and pneumatic systems and components. This role will have a broad scope of responsibility from creating electrical and pneumatic, to developing and executing software test plans, writing test reports and system level troubleshooting.

ESSENTIAL DUTIES AND RESPONSIBILITIES:

• Creates documentation as primary responsibility.

• Troubleshoots system level components and software.
• Assists with functional design teams to aid designers with tasks such as schematic diagrams, test documents, and user manuals.
• Sets up, adjusts, and works with control system hardware.
• Supports and/or installs PLC and PC based software applications, participates in testing process through development of software testing routines and test witnessing.
• Supports testing done by internal and external laboratories.
• Communicates with independent testing companies when certifications are required.
• Utilizes test equipment during the debugging and troubleshooting of automation control systems.
• Evaluates and improves production methods and processes.
• Reviews existing products suggests improvements and implements changes to reduce costs and improve quality.
• Ad-hoc projects as needed

QUALIFICATIONS:

To perform this job successfully, an individual must be able to perform each essential duty satisfactorily. The requirements listed below are representative of the knowledge, skill, and/or ability required. Reasonable accommodations may be made to enable individuals with disabilities to perform the essential functions.

EDUCATION AND/OR EXPERIENCE

• Bachelor's degree in electrical engineering or relevant degree preferred.
• 0-3 years of professional experience in a related role.

KNOWLEDGE, SKILLS, AND ABILITIES:  

• Basic understanding of electrical, electronic, mechanical, hydraulic, and pneumatic systems.
• Fundamental troubleshooting skills for system-level components and software.
• Ability to assist in documentation tasks (schematic diagrams, test documents, user manuals).
• Exposure to PLC and PC-based software applications and ability to support basic installations.
• Familiarity with test equipment used for debugging and troubleshooting automation control systems.
• Basic ability to evaluate and suggest improvements for production methods.
• Ability to set up, adjust, and work with control system hardware.

TRAVEL:

• Up to 10% for travel, if needed.

PHYSICAL DEMANDS & WORK ENVIRONMENT:

The physical demands of the role involve prolonged periods of sitting at a desk, using a computer, and engaging in repetitive hand movements for tasks like typing or writing. Occasional standing, walking, and lifting objects up to 20 pounds may be required. This role may also include frequent use of standard office equipment such as printers, copiers, and telephones. Good vision and hearing are needed to perform tasks effectively and communicate with team members. Vision requirements are the ability to adjust focus and identify and distinguish colors.

The work environment for this role is primarily an office setting located near a manufacturing facility. While the office is climate-controlled and typically quiet, occasional exposure to noise, vibrations, or odors from the nearby production area may occur. Employees may need to enter the manufacturing floor occasionally, requiring adherence to safety protocols, including wearing appropriate personal protective equipment (PPE).

At Barry-Wehmiller we recognize that people come with a wealth of experience and talent beyond just the technical requirements of a job.  If your experience is close to what you see listed here, please still consider applying.  We know that our differences often can bring about innovation, excellence and meaningful work—therefore, people from all backgrounds are encouraged to apply to our positions.  Please let us know if you require reasonable accommodations during the interview process. ​

Barry-Wehmiller is an equal opportunity employer. M/F/D/V This organization uses E-Verify.Applicants may be subject to pre-employment screening which may include drug screening, reference checks, employment verifications, background screening and/or skills assessments.

Company:

Machine Solutions, Inc.