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Principal, Process Controls Engineer

Barry-Wehmiller · Oak Brook, IL · Full time

Posted Sep 1, 2026 · We last checked this listing on Oct 6, 2026

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Likely interview questions for this role

Written from this job description, not a generic list. Each one notes what the interviewer is really checking.

About your past

Tell me about a startup where a control loop or sequence didn't behave as designed. How did you find the problem?

What they are checking: Whether they troubleshoot calmly and methodically under schedule pressure at a client site.

How do you review junior engineers' code and configuration without slowing a project down?

What they are checking: Whether they build quality and people at the same time, which principals in a consulting firm are expected to do.

Tell me about a time you had to explain a controls decision to a client executive who wasn't technical.

What they are checking: Whether they can translate technical choices into business terms the client cares about.

What would you do

A client's operators want manual overrides everywhere and your design team thinks that's unsafe. How do you resolve it?

What they are checking: Whether they can balance what operators want against safety and good practice, and explain the tradeoff clearly.

About the work

Walk me through a process control system you designed from P&IDs through startup.

What they are checking: Whether they have owned controls design end to end, which a principal role expects.

Which DCS and PLC platforms have you worked on most deeply, and how do you choose between them for a client?

What they are checking: Whether they can make platform recommendations based on the process and client needs, not habit.

How do you approach ISA-88 batch control design for a food or life sciences plant?

What they are checking: Whether they understand batch structure and recipe management, which is common in the industries this firm serves.

How do you handle validation requirements like 21 CFR Part 11 when designing a controls system for a life sciences client?

What they are checking: Whether they build compliance into the design from the start, since rework for validation is very costly.

How do you estimate controls hours for a proposal when the process scope is still vague?

What they are checking: Whether they can price work responsibly, since bad estimates hurt both the firm and the client relationship.

What's your approach to alarm management so operators don't get flooded?

What they are checking: Whether they think about the human running the system, which separates good controls design from merely working code.

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The full job description

As published by Barry-Wehmiller.

About Us: BW Design Group is a fully integrated architecture, engineering, construction, system integration, and consulting firm committed to helping our clients realize their most critical goals from Strategy to Commercialization. As the only firm born from a manufacturing technology company to become an independent and fully integrated firm, we combine deep domain expertise in the manufacturing environment with an approach that is built to serve the dynamic needs of our clients. Rooted in our distinct culture of Truly Human Leadership, we cultivate the leaders who will define tomorrow and partner with our clients in the food & beverage, life sciences, industrial, and advanced technology industries to build the future of manufacturing and technology. Barry-Wehmiller is a diversified global supplier of engineering consulting and manufacturing technology for the packaging, corrugating, sheeting and paper-converting industries. By blending people-centric leadership with disciplined operational strategies and purpose-driven growth, Barry-Wehmiller has become a $3 billion organization with nearly 12,000 team members united by a common belief: to use the power of business to build a better world. Job Description: Who You’ll Work With You will join one of our 45 offices in the US, be part of a committed team of over 1500 professionals, and work in teams and directly with our clients doing work that is shaping the world around us. You will be welcomed into a rapidly growing business and team and empowered to make an impact. You will be valued, cared for, and challenged on your path to becoming a world-class professional consultant and surrounded by leaders who are committed to creating an environment that enables you to realize your own success and fulfillment. When you join Design Group as a Principal Process Controls Engineer, you are joining a team that will challenge you and position you for growth. Design Group is widely known as an industry leader, recognized as a top system integrator, ranking #9 in the 2025 System Integrator Giants; as a Rockwell Platinum Integrator, the highest designation given to Rockwell partners; and as an Ignition Enterprise Premier Integrator. As a part of this team, you will learn from industry leading experts and may even have the chance to be an active participant in industry events like the Ignition Build-A-Thon which Design Group won in 2023! As a Principal Process Controls Engineer, you will play a critical leadership role within Design Group’s Control System Integration Practice. You will collaborate with seasoned leaders, technical specialists, and subject matter experts to deliver innovative, top-tier solutions to our clients and help define the direction and standards for process controls in the food & beverage industry. What You’ll Do You'll work individually and in teams to support capital projects and implement solutions for our clients. Together, you will help our clients make critical changes to improve their performance and realize their most important goals. • Serve as a subject matter expert and technical authority for the firm for process control systems, with mastery in FactoryTalk Batch, PlantPAx, and ISA-88 (S88) batch controls. • Spearhead project teams through complex automation project life cycles, ensuring technical excellence and accountability across all phases—from conceptual design to site startup and client handover. Ensure that project delivery meets quality, schedule, and cost targets and that solutions comply with all regulatory, safety, and security standards. • Mentor, develop, and review the work of engineers at all levels, elevating the technical expertise of the organization. • Support the development and implementation of firmwide standards and best practices for process automation and controls in manufacturing environments. • Partner directly with key clients to understand needs, define project requirements, articulate solutions, and build lasting relationships based on trust and delivery of world-class outcomes. • Champion client-focused innovation, evaluating new technologies and creative approaches to deliver exceptional value, quality, and performance. • Participate in business development strategy, project opportunity reviews, and proposal preparation for high-value and complex projects. What You’ll Bring • Minimum of 15 years of progressive process controls engineering experience, including significant leadership roles and client-facing responsibilities in manufacturing environments. • Mastery of FactoryTalk Batch, Rockwell PlantPAx, and thorough understanding and application of ISA-88 (S88) batch process control standards. • Substantial experience with process instrumentation, industrial networking, PLC/SCADA architectures, and integration with process systems. • Demonstrated history of leading teams in the successful delivery of automation projects. • Outstanding communication skills with the ability to inspire teams, engage with clients at executive and plant levels, and convey complex technical information clearly to all audiences. • Experience with proposal development, project estimation, and scope definition for controls projects. • Aptitude for troubleshooting, creative problem solving, and delivering innovative technical solutions in demanding environments. • Recognition as a technical leader or subject matter expert in professional or industry settings; participation in conferences or standards committees is a plus. • Willingness to travel as required for project and client needs, including installations, startup support, strategic meetings, training, and industry events. • Bachelor’s degree in Electrical, Chemical, or Mechanical Engineering (Master’s and/or Professional Engineer (PE) license preferred). Our culture and commitment to our people is what sets us apart. We foster an environment of mutual respect, integrity, and unconditional interest in the individual and collective success of our professionals. Our model and entrepreneurial mindset offer a rewarding, challenging, and highly flexible path. As a Principal Process Controls Engineer, you will build a meaningful and fulfilling career with the support of professional development resources and mentorships including our First Year Experience program, Individual Development Plans, and Career Path resources and tools. You will be surrounded by exceptional talent who will support your development as both a world-class engineer and a highly effective leader. Feel like you're on the path to becoming a Principal Process Controls Engineer but you're not quite there yet? We'd love to connect with you to see if we can take you from where you are today and grow you into a Design Group Engineering Consultant. #LI-KM1 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: Design Group

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