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Senior Controls Engineer

Barry-Wehmiller · Oak Brook, IL · $120,000–$160,000 a year · 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 the system didn't behave as expected. How did you find the issue?

What they are checking: Whether they troubleshoot systematically and stay calm on site when the client is watching.

Tell me about a time you mentored a junior controls engineer.

What they are checking: Whether they share knowledge and raise team quality, which senior engineers are expected to do.

What would you do

A client's maintenance team wants code they can understand, but your design uses advanced techniques. How do you balance that?

What they are checking: Whether they design for the people who will support the system after the integrator leaves.

How do you handle a scope change the client requests during commissioning?

What they are checking: Whether they protect the project commercially while still keeping the client relationship positive.

About the work

Walk me through a PLC program you designed from scratch. How did you structure it?

What they are checking: Whether they write organized, maintainable code that other engineers and plant staff can support later.

Which PLC and HMI platforms do you know best, and how deep is that knowledge?

What they are checking: Whether they have real senior-level depth on platforms common in manufacturing automation.

How do you approach writing a functional specification before programming starts?

What they are checking: Whether they design and agree on behavior up front, which prevents expensive changes during startup.

How do you design control panels and I/O to meet safety standards like NFPA 79 or functional safety requirements?

What they are checking: Whether they treat machine and process safety as a design requirement rather than an add-on.

How do you estimate controls hours for a project proposal?

What they are checking: Whether they can price work realistically, which affects both firm profit and client trust.

What's your experience integrating PLC systems with MES or plant data systems?

What they are checking: Whether they understand how controls connect to higher-level systems that manufacturing clients increasingly want.

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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 Senior 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! In this role, you will work with a team of industry experts to help the world’s leading companies solve their most difficult problems. You will join our Control System Integration Practice and partner with seasoned leaders, technical specialists, and subject matter experts to deliver the highest quality solutions to our clients with consistency and accuracy. 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. • Design automation control systems; develop project specifications, documentation, and drawings for a variety of high speed and other automated manufacturing processes • Participate in various automation project phases including software configuration and testing, commissioning, installation, and start-up • Assume accountability for complete project execution including team leadership, SCADA design, PLC and HMI programming, and site start-up support of integrated systems • Maintain and grow solid client relationships • Troubleshoot packaging lines, process systems, and software systems • The ability to successfully execute multiple project responsibilities with minimal supervision • Make an impact day-to-day with your skills and expertise, strengthening that relationship with our clients and team What You’ll Bring • A minimum of 5-7 years of related automation experience with HMI, SCADA, PLCs, and general control system design • Packaging and process controls experience in the consumer products, life sciences, or beverage/brewery/food industries (preferred) • Experience with Allen-Bradley (ControlLogix, CompactLogix, PLC5, SLC500) PLCs, PanelView/PanelviewPlus HMIs, Industrial Communication Networks (Ethernet, EthenetI/P, DeviceNet, DH+) • Experience with FactoryTalk Suite, IntellutionSuite, Wonderware Suite, and VisualBasic/C#/Java (preferred) • Engineering consulting experience (preferred) • The ability to successfully interact with clients • Solid skills at troubleshooting and performing in high intensity environments • Excellent communication, organizational, and interpersonal skills • Superior analytical and problem-solving skills • A willingness to travel for project requirements including installation and start-up activities, client and company sponsored meetings, trainings, industry related seminars, forums, and conventions • A bachelor of science in electrical, mechanical, or chemical engineering, or a related degree (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 Senior 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 Senior 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. The approximate pay range for this position is $120,000 - $160,000 per year. Please note that the pay range provided is a good faith estimate for the position at the time of posting. In addition to base compensation, this position is eligible for variable compensation based on individual and/or company performance, in accordance with the terms of the applicable plan. Final compensation may vary based on factors including but not limited to background, knowledge, skills, and abilities as well as geographic location of the position. #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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