Senior Engineer - Controls

About Us:

Job Description:

Join Us. Build a Better World Through Business.

At Barry-Wehmiller Companies, we believe business can be a powerful force for good. Headquartered in St. Louis, Missouri, we are a global leader in manufacturing technology and services. Since our founding in 1885 as a maker of brewing machinery, we’ve grown through the acquisition of more than 80 companies, serving industries such as packaging, paper converting, sheeting, corrugating, engineering, and IT consulting. In 2016, we ranked No. 10 on the St. Louis Business Journal list of the city’s Top 150 Privately Held Companies.

What truly sets us apart is our culture-rooted in Truly Human Leadership, a philosophy that prioritizes the well-being and growth of every individual. We measure success by the way we touch lives, not just by financial results.

In India, Barry-Wehmiller operates as a hub of innovation and collaboration through our Global Competency Center (GCC) and other strategic functions. The GCC houses centers of excellence in engineering, content management, sourcing, software development, global IT operations, and shared financial services-providing critical support to Barry-Wehmiller divisions worldwide.

Our culture is built on:

· Ownership - Drive features end-to-end, from design to deployment.

· Flexibility - A friendly, results-oriented environment that respects your time.

· Empowerment - Your ideas matter, and your work creates visible impact.

· Learning and Growth - Tackle complex challenges alongside passionate peers, with continuous support for your development.

Career Development and Global Exposure

At Barry-Wehmiller, your growth is our priority. You’ll have access to world-class learning programs, leadership development opportunities, and mentorship from industry experts. Our global footprint means you’ll collaborate with teams across continents, gaining exposure to diverse markets, cutting-edge technologies, and best practices from around the world. Whether you aspire to deepen your technical expertise or take on leadership roles, we provide the resources and support to help you thrive.

If you’re ready to bring your best thinking to a high-impact, future-focused environment-where long-term stability meets start-up agility-and be part of a company that cares deeply about people, we’d love to hear from you.

Job Description

We are looking for a Senior Engineer - Controls with 8+ years of experience in the design, development, modification, migration, integration, and implementation of PLC and HMI/SCADA systems for discrete machinery and equipment.

The ideal candidate will have strong hands-on experience with a combination of Siemens, Allen-Bradley (Rockwell Automation), and Beckhoff automation platforms. Experience in printing, paper converting, packaging, textile, or other machinery/OEM industries is highly preferred.

The engineer should be able to take a systems approach to understand the overall machine design, mechanical functions, electrical architecture, control philosophy, safety systems, and automation requirements, and develop robust PLC and HMI programs ensuring the overall functional quality and performance of the machinery/equipment.

The role will be responsible for the interface between electrical hardware, PLC software, HMI/SCADA, drives, motion systems, instrumentation, and machine-level automation.

Technical Skills

PLC & HMI Platforms

Strong hands-on experience in one or more of the following platforms, with the ability to work across multiple automation platforms:

• Siemens S7-1200 / S7-1500 PLCs
• Siemens Comfort Panels / Unified Comfort Panels
• Allen-Bradley / Rockwell Automation PLCs
  • ControlLogix
  • CompactLogix
• Beckhoff PLC / IPC-based control systems
  • TwinCAT 3
  • EtherCAT
• Experience with HMI/SCADA development and integration across Siemens, Allen-Bradley, and Beckhoff platforms.

PLC & HMI Development

• Hands-on experience developing PLC and HMI programs from scratch based on URS, functional specifications, and client standards.
• Ability to understand and develop PLC programs using:
  • Ladder Logic
  • Function Block Diagram
  • Structured Text
  • Sequential Function Chart
• Develop machine sequences, interlocks, alarms, permissives, recipes, diagnostics, and operator interfaces.
• Interface PLC programs with HMI/SCADA systems.
• Experience in modifying, debugging, migrating, and optimizing existing PLC/HMI programs.
• Experience with machine-level automation and discrete manufacturing applications.
• HMI scripting/programming experience using JavaScript, C#, or similar technologies is an added advantage.

Siemens Automation

• Strong hands-on experience with Siemens S7-1500 PLCs.
• Experience with TIA Portal V15.1 or above.
• TIA Portal V17/V18/V19 or later experience preferred.
• Siemens Comfort and Unified Comfort HMI development.
• PLC/HMI programming, troubleshooting, commissioning, and debugging.
• Experience with Siemens drives and motion systems is preferred.

Allen-Bradley / Rockwell Automation

• Hands-on experience with Allen-Bradley PLCs.
• Experience with ControlLogix and/or CompactLogix platforms.
• Rockwell Studio 5000 / RSLogix programming experience.
• Allen-Bradley HMI experience using FactoryTalk View is preferred.
• Experience with Rockwell drives, I/O, communication networks, and motion systems is an advantage.

Beckhoff Automation

• Hands-on experience with Beckhoff PLC/control systems.
• Experience with TwinCAT 3 programming and development.
• Knowledge of EtherCAT communication and distributed I/O systems.
• Experience with Beckhoff IPCs, motion control, servo systems, and drives is preferred.
• Experience developing machine control applications using Structured Text is an advantage.

Industrial Communication & Networking

Good understanding of industrial communication protocols and networking, including:

• PROFINET / PROFIBUS
• EtherNet/IP
• EtherCAT
• AS-i
• CAN / CANopen
• DeviceNet
• Modbus TCP/RTU
• OPC UA
• Other industrial Ethernet and fieldbus protocols

Ability to configure, troubleshoot, and integrate PLCs, remote I/O, drives, HMIs, sensors, and other automation devices over industrial networks.

Drives, Motors & Motion Control

• Knowledge of selection and application of motors, motor controllers, VFDs, servo drives, and motion-control systems.
• Understanding of:
  • Motor horsepower
  • Torque
  • Speed range
  • Gear ratios
  • Reduction ratios
  • Acceleration/deceleration
• Experience with Siemens, Allen-Bradley, or Beckhoff drives is preferred.
• Basic understanding of servo positioning and motion-control applications.

Instrumentation & Control Components

Good understanding of selection and application of industrial control components, including:

• Sensors for flow, pressure, level, temperature, position, speed, counters, motion, vision, etc.
• Digital and analog sensors
• Proximity and photoelectric sensors
• Encoders
• Transducers
• Solenoid valves
• Relays
• Contactors
• On/Off control devices
• Analog I/O and signal conditioning
• A/D and D/A conversion
• I/P and P/I conversion

Understanding of sensor characteristics such as accuracy, precision, response time, repeatability, reliability, range, and environmental/temperature effects.

FAT, SAT & Commissioning

• Develop automation test cases and procedures for Factory Acceptance Testing (FAT) and Site Acceptance Testing (SAT).
• Participate in FAT/SAT with customers and project teams.
• Hands-on experience in machine installation, commissioning, troubleshooting, and start-up.
• Ability to troubleshoot PLC, HMI, drives, I/O, communication, and machine sequence issues.
• Experience with remote commissioning and troubleshooting tools.
• Willingness to travel to customer sites for commissioning and project support.

Standards & Compliance

Working knowledge of applicable industry codes, standards, and regulations such as:

• ANSI
• ISA
• NEC
• NEMA
• NFPA
• OSHA
• UL

Experience working with machine safety systems and safety PLCs is an added advantage.

Tool Skills

Mandatory / Core

• Siemens TIA Portal - V15.1 or above
• Siemens S7-1500 PLC
• Siemens Comfort / Unified Comfort HMI
• Allen-Bradley / Rockwell Studio 5000
• ControlLogix / CompactLogix
• Beckhoff TwinCAT 3
• EtherCAT

Preferred

• TIA Portal V17+
• FactoryTalk View
• Siemens / Rockwell / Beckhoff drives and motion systems
• OPC UA
• Industrial Ethernet networking
• HMI scripting / C# / JavaScript
• EPLAN or similar electrical engineering tools

Education & Experience

• Bachelor's degree in Electrical & Electronics Engineering (EEE), Electronics & Communication Engineering (ECE), Instrumentation, or related engineering discipline.
• 8+ years of experience in industrial automation and controls engineering.
• Strong hands-on experience in PLC and HMI programming.
• Experience with a combination of Siemens, Allen-Bradley, and Beckhoff platforms is strongly preferred.
• Demonstrated experience developing PLC/HMI programs from scratch.
• Experience in machinery/OEM applications is highly preferred.
• Experience in printing, packaging, paper converting, textile, or other discrete machinery industries is an advantage.
• Experience in machine commissioning and customer-site support is preferred.

Key Result Areas

• Configure automation hardware and software according to project design specifications.
• Develop PLC and HMI programs from scratch based on machine automation requirements.
• Integrate Siemens, Allen-Bradley, and Beckhoff automation platforms with machine hardware and control systems.
• Ensure optimal performance, reliability, quality, and responsiveness of PLC/HMI applications.
• Troubleshoot PLC, HMI, drives, motion, I/O, and industrial communication issues.
• Follow software development, change-management, and version-control procedures.
• Maintain proper documentation of PLC/HMI software and project changes.
• Manage assigned projects and deliver according to agreed schedules and scope.
• Communicate project progress, technical issues, and risks to project stakeholders.
• Support FAT, SAT, machine start-up, commissioning, and customer acceptance.
• Provide technical support to internal teams and customers as required.

Soft Skills

• Strong verbal and written communication skills.
• Logical and systematic approach to problem-solving.
• Strong troubleshooting and analytical skills.
• Ability to understand complex machine sequences and identify key technical issues.
• Ability to work independently as well as collaboratively within a multidisciplinary team.
• Strong customer-facing and interpersonal skills.
• Ability to manage multiple priorities and changing project requirements.
• Willingness to learn and work across multiple automation platforms.

Travel

Occasional domestic and/or international travel may be required, up to 15%, for customer meetings, FAT, SAT, installation, commissioning, troubleshooting, and project support.

Preferred Candidate Profile

The ideal candidate will be a multi-platform Controls Engineer with strong practical experience in:

Siemens + Allen-Bradley + Beckhoff

with hands-on capability in:

PLC Programming → HMI Development → Drives/Motion → Industrial Communication → Machine Integration → FAT/SAT → Commissioning

Experience with OEM/discrete machinery, particularly printing, packaging, paper converting, or textile machinery, will be a strong advantage.

Barry-Wehmiller is committed to creating a people-centric workplace where employees can bring their best selves to the work they do and grow through meaningful career opportunities.

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.

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