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Carex Consulting Group Logo Carex Consulting Group · IT - Software Development

Process Controls Engineer

United States, Portage · Job Posted May 29, 2026
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Job Description

Carex is partnering with a chemical manufacturing industry partner to hire an Process Controls Engineer based in Portage, Wisconsin. This role serves as the primary technical resource responsible for the reliability, maintenance, and continuous improvement of PLCs, HMIs, and plant electrical power distribution systems. The Process Controls Engineer supports daily operations and capital improvement projects by troubleshooting control system issues, optimizing system performance, and implementing solutions that improve safety, reliability, and production efficiency. This position supports multiple sites and includes travel between locations as needed, along with 24/7 on-call support outside of approved vacation periods.

Job Responsibility

  • Maximize uptime and minimize interruptions to plant control systems and production equipment
  • Improve the reliability, stability, and performance of PLCs, HMIs, and industrial control systems
  • Design, implement, and manage plant electrical power distribution systems and control system applications
  • Deliver electrical and controls project scopes on time and within approved budgets
  • Travel between Portage and Appleton sites to support, maintain, and improve control systems
  • Troubleshoot and resolve plant control system issues to support production efficiency and product quality
  • Identify and implement projects related to control system obsolescence and reliability improvements
  • Manage control system service contracts and vendor relationships to maximize value
  • Develop and recommend electrical specifications in compliance with applicable standards, codes, and best practices
  • Review, approve, and release detailed electrical drawings for production, construction, and installation
  • Coordinate project work for engineers, programmers, and CAD designers while providing technical oversight
  • Communicate project status, risks, mitigation strategies, and improvement opportunities to stakeholders
  • Manage project execution through routine status reviews and cross-functional coordination
  • Prepare capital project requests outlining scope, schedule, resource requirements, and business justification
  • Track project costs against budgets and provide regular updates to management and project teams
  • Apply Lean and Continuous Improvement principles to improve control systems, communications, quality, and reliability
  • Evaluate maintenance strategies and recommend spare parts inventories to support reliable operations
  • Participate in quarterly capital planning activities to support long-term investment planning
  • Adhere to all plant safety policies, regulatory requirements, and quality standards

Requirements

  • Associate degree in Electrical Engineering or a closely related technical field
  • Minimum of 1 year of industrial electrical or controls engineering experience
  • Ability to travel up to 25% between multiple manufacturing sites
  • Hands-on experience with Allen-Bradley / Rockwell Automation PLC platforms
  • Experience developing and supporting HMI applications
  • Knowledge of plant-level electrical power distribution systems
  • Experience with process integration and optimization
  • Understanding of industrial instrumentation and the ability to specify instrumentation requirements for projects
  • Strong project management, prioritization, organization, and multitasking capabilities
  • Proficiency with Rockwell Studio 5000 and FactoryTalk software
  • Working knowledge of AutoCAD, AutoCAD Electrical, Microsoft Office Suite, and Microsoft Project
  • Excellent verbal, written, and interpersonal communication skills
  • Ability to collaborate effectively with operators, engineers, contractors, and cross-functional stakeholders
  • Proven ability to proactively identify and resolve operational or project-related issues
  • Continuous improvement and Kaizen mindset
  • Experience presenting technical information to leadership and stakeholders
  • Commitment to plant safety, quality standards, and regulatory compliance

Nice to have

  • Associate’s degree in Electrical Engineering or a closely related technical field
  • 1–3 years of experience supporting industrial control systems in a manufacturing environment
  • Experience in chemical, pharmaceutical, or liquid food processing facilities
  • Familiarity with PlantPAx 5.0 and OSI PI products
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