Controls Emulation Engineer

We are seeking a detail-oriented and technically skilled Emulation Engineer to support the design, development, and testing of warehouse control systems through virtual commissioning using emulation tools. The ideal candidate will work closely with automation engineers, software developers, and operations teams to simulate and validate the integration of Warehouse Management Systems (WMS), Warehouse Control Systems (WCS), and material handling equipment (MHE).

• Develop, configure, and maintain emulation models for warehouse automation systems, including conveyors, sorters, AS/RS, AGVs, and pick/pack stations.
• Preferably use Rockwell Emulate3D in developing systems controlled by PLC programs.
• Knowledge in other emulation platforms (Siemens Plant Simulation, FlexSim,) is welcomed.
• Emulate system behavior and performance.
• Integrate emulation models with WMS/WCS/PLC controls to support system testing and validation.
• Support functional testing and virtual commissioning activities prior to on-site deployment.
• Troubleshoot and debug software, control logic, and integration issues using emulated environments.
• Collaborate with software engineers, controls engineers, and system integrators to verify system logic, throughput, and operational scenarios.
• Provide feedback on design optimization based on emulation performance analysis.
• Document test cases, test results, and emulation models for traceability and future reference.
• This position manages all employees of the department (6-8) and is responsible for the performance management and hiring of the employees within that department.

Requirements

• Bachelor’s degree in Engineering, Computer Science, Mechatronics, or related field.
• 3+ years of experience in emulation, simulation, or controls engineering, preferably in warehouse automation.
• Hands-on experience with emulation/simulation platforms (e.g., Emulate3D, Siemens Plant Simulation, or similar).
• Understanding of WMS/WCS operations and industrial automation systems.
• Familiarity with PLC logic, industrial communication protocols (e.g., OPC UA, Modbus), and material flow concepts.
• Strong problem-solving, analytical, and debugging skills.
• Excellent communication and teamwork abilities.
• Experience in virtual commissioning or digital twin technologies.
• Knowledge of scripting languages (Python, C#, Java, or similar).
• Experience with logistics and e-commerce warehouse environments.
• Experience worked on Scada, HMI and Ignition programs
• Knowledge of using systems such as Rockwell- Studio 5000 Logix Emulate
• Hybrid or on-site depending on project requirements.
• May require occasional travel to customer or project sites.
• Fast-paced, project-driven environment.

Benefits

• Medical Insurance

• Dental Insurance

• Vision Insurance

• Health Care Concierge Service

• 401(k) Retirement Plan (Pre-tax & Roth)

• Company paid Basic Life Insurance, Short-Term Disability & Long-Term Disability

• Voluntary Life & AD&D Insurance

• Voluntary Accident, Critical Illness & Hospital Indemnity Insurance

• Pet Insurance

• Milk Stork Program

• Wellness Program with gift card redemption and wellness challenges

• Paid Time Off (Vacation, Sick & 10 Holidays)

• Training & Development
  KPI Solutions provides equal employment opportunity to all individuals regardless of their race, color, creed, religion, gender, age, sexual orientation, national origin, disability, veteran status, or any other characteristic protected by states, federal, or local law.