System Architecture, Standards & Tooling

• Design and develop PLC and HMI architectures for moderately to highly complex automation systems
• Contribute to and maintain reusable PLC/HMI code libraries, configuration templates, and engineering standards
• Define and manage the I/O contract between PLC libraries (UDTs/AOIs/DUTs) and emulation objects, including virtual-mode hooks and diagnostic structures
• Ensure alignment between standard PLC/HMI libraries and the emulation component catalog, including version control, migration notes, and Git/GitHub workflows

Emulation Platform Ownership

• Build, maintain, and expand a reusable emulation component catalog (transport, merges, gapping, scanning, diverters, recirculation; roadmap to advanced sortation)
• Establish and document fidelity guidelines, modeling assumptions, and system limits
• Develop automated FAT harnesses (scripted test decks, pass/fail gates, reporting) tied to design documents and performance metrics
• Create layout assembly tools and workflows to rapidly build or reconfigure models from ECAD/CAD
• Ensure parity between emulated and live systems to reduce on-site time, cost, and risk

Technical Leadership & Execution

• Program, test, and commission control systems—including conveyors, merges, and moderate sortation logic—both virtually and on-site
• Lead FAT/SAT activities, troubleshooting escalations, and commissioning strategies
• Develop and maintain project deliverables, version control, and quality assurance processes
• Contribute targeted PLC/HMI development, including device AOIs, diagnostics, Ignition widgets, gateway scripts, and position tracking

Cross-Functional & Customer Collaboration

• Serve as a technical point of contact and coordinate integration across Mechanical, Electrical, and Software disciplines
• Define CAD markup standards (mass, friction, materials, sensor faces, elevations) to improve model fidelity and reduce rework
• Partner with Project Management and Sales to scope projects, establish acceptance criteria, and present emulation results to internal and external stakeholders
• Provide technical direction and oversight to subcontractors and integration partners

Team Development, Mentorship & Culture Building

• Mentor engineers through hands-on guidance, structured peer reviews, onboarding, and training
• Develop playbooks, “golden example” projects, and internal training materials that enable engineers to independently build and extend emulation models
• Promote a simulation-first, standards-driven engineering culture focused on measurable outcomes such as hours saved, defects prevented, and accuracy versus on-site results

Strategic Growth & Innovation

• Identify and lead improvement initiatives related to commissioning efficiency, code reusability, testing accuracy, and HMI experience
• Pilot new tools, features, or platforms that enhance controls engineering and emulation capabilities
• Contribute to internal R&D efforts and share findings that inform roadmap development and engineering best practices

Education and Experience

• Bachelor’s degree in Electrical Engineering, Mechatronics, or a related field
• The client is seeking candidates at two senior levels:
• 5–7 years of experience in industrial controls engineering, including lead project responsibilities
• 7+ years of experience in industrial controls or virtual commissioning, including hands-on PLC/HMI work and model-based testing
• Demonstrated experience leading emulation or virtual commissioning efforts tied directly to real PLC code (not visualization-only)

Technical Skills

• PLC Programming: Advanced proficiency in Rockwell Studio 5000 (AOIs/UDTs/ST); experience with TIA Portal; Beckhoff TwinCAT (ST/POUs/DUTs) a plus
• Emulation & Digital Twins: Exposure to Emulate3D or equivalent, including custom component catalogs, scripted test decks, virtual-mode diagnostics, and automated FAT harnesses
• HMI/SCADA: Ignition (Perspective/Vision), FactoryTalk View; alarm configuration, historian basics, and security (roles/IdP)
• Industrial Networks & Devices: Ethernet/IP (preferred), Profinet, OPC UA; VFDs, servo drives/motion, scanners, safety systems, and device-level diagnostics

Leadership & Professional Skills

• Systems thinker with the ability to break down complex controls and emulation challenges into clear, testable components
• Strong communicator, effective with customers, vendors, and cross-functional engineering teams
• High documentation discipline with strong version-control awareness and adherence to engineering standards
• Proven ability to manage multiple projects simultaneously while mentoring and developing junior engineers
• Collaborative leadership style focused on measurable outcomes, continuous improvement, and cross-team alignment
• Ability to read and interpret technical specifications, professional journals, and engineering drawings, and to produce clear technical documentation
• Willingness to travel up to 30% for commissioning, installations, and on-site support

Compensation range: $115,000 - $150,000 DOE