Controls Engineer

Job Title: Controls Engineer

Job Description

This Controls Engineer role focuses on developing and deploying device-level analytics solutions for manufacturing operations. You will leverage PLC-based data collection and Python-based analytics to identify emerging equipment issues, reduce downtime, and enable proactive maintenance actions. The position centers on creating software applications that collect and analyze data from production equipment across multiple manufacturing plants, generating insights into throughput, efficiency, performance, and other key operational metrics.

Responsibilities

• Develop, test, and deploy PLC logic to collect critical operational data from manufacturing equipment while ensuring minimal disruption to production.

• Analyze, understand, and troubleshoot existing PLC programs and machine control logic to improve reliability and performance.

• Extract operational and diagnostic data from existing PLC programs and manufacturing systems to support device-level analytics.

• Modify, update, test, and deploy PLC code on live equipment, maintaining safe and continuous operations.

• Design, develop, validate, and standardize controls device data parsing PLC logic to support analytics and reporting.

• Own and update automated PLC logic generation tools to streamline deployment and configuration across multiple plants.

• Develop PLC logic for Rockwell, Siemens, and Fanuc platforms, integrating with programming languages such as Python and C++ where appropriate.

• Ensure compliance with common controls hardware and software strategies when implementing new device-level analytics controls solutions.

• Ensure adherence to plant floor systems, networking, and cybersecurity requirements in all controls and analytics implementations.

• Collaborate with core analytics teams, business stakeholders, IT, automation specialists, and the broader analytics community to capture requirements, prioritize initiatives, and plan deployments.

• Support controls, networks, and IT architects in developing and testing necessary controls software and integrating device-level analytics logic into core PLC templates.

• Create and maintain training documents, standardized work instructions, and reference materials to support consistent implementation and knowledge transfer.

• Monitor and understand the latest industry trends in advanced analytics tools and explore opportunities to apply them in manufacturing environments.

• Review observations from manufacturing plants, propose improvement solutions, and provide feedback to enhance device-level analytics strategies.

• Provide training, guidance, and support to controls execution teams, strategic suppliers, and plant personnel as needed during deployments and upgrades.

• Travel to manufacturing facilities on an as-needed basis to support pilots, testing, training, upgrades, and commissioning of analytics and controls solutions.

• Connect Python-based analytics solutions to plant equipment, validate data collection processes, and ensure successful implementation within production environments.

Essential Skills

• 2+ years of experience in industrial automation, controls engineering, or manufacturing automation.

• Experience working in automotive powertrain manufacturing environments such as propulsion systems facilities, engine plants, or similar operations.

• Strong hands-on PLC programming experience, including Siemens PLC programming using STEP 7 and TIA Portal.

• Experience with Rockwell Automation (Allen-Bradley) PLCs, including troubleshooting and debugging.

• At least 1 year of Allen-Bradley PLC experience, which may include academic or project-based work.

• Intermediate-level Python programming skills, including data extraction, data analysis, and automation scripting.

• Demonstrated ability to develop, modify, and deploy PLC logic on live production equipment.

• Ability to travel as needed to manufacturing plants across the United States.

• Ability to work primarily from a technical center location while coordinating activities with multiple plant sites.

Additional Skills & Qualifications

• Experience in automotive OEM or Tier-1 supplier environments.

• Experience working with automation integrators such as GROB, KUKA, Comau, or Valiant.

• Familiarity with Fanuc controls and PLC platforms.

• Experience developing PLC logic that interfaces with higher-level programming languages such as Python and C++.

• Understanding of common controls hardware and software strategies and standards used in large manufacturing organizations.

• Knowledge of plant floor systems, industrial networking, and cybersecurity requirements.

• Ability to create clear training documents and standardized work instructions for technical audiences.

• Interest in and awareness of the latest industry trends in advanced analytics tools and manufacturing data solutions.

• Strong problem-solving skills and the ability to propose practical improvement solutions based on observations from manufacturing plants.

• Comfort with supporting pilots, tests, trainings, and system upgrades in active production environments.

Work Environment

This role is primarily based at a technical center in Warren, Michigan, where most software development and analytics platform design work is performed. The position involves working closely with manufacturing and engineering teams in an office and lab environment, with regular interaction with plant floor equipment and controls systems. You will travel several times per month, typically 2-3 days, to manufacturing sites across the United States to integrate Python-based analytics software into production machines, support commissioning, and validate data collection. The work environment includes exposure to industrial automation technologies such as Siemens, Rockwell (Allen-Bradley), and Fanuc PLCs, as well as plant floor systems, industrial networks, and cybersecurity-controlled infrastructures. Travel days may involve time on the production floor, where appropriate safety and attire guidelines are followed according to plant standards.

Job Type & Location

This is a Permanent position based out of Detroit, MI.

Pay and Benefits

The pay range for this position is $35.00 - $44.00/hr.

Eligibility requirements apply to some benefits and may depend on your job classification and length of employment. Benefits are subject to change and may be subject to specific elections, plan, or program terms. If eligible, the benefits available for this temporary role may include the following: - Medical, dental & vision - Critical Illness, Accident, and Hospital - 401(k) Retirement Plan - Pre-tax and Roth post-tax contributions available - Life Insurance (Voluntary Life & AD&D for the employee and dependents) - Short and long-term disability - Health Spending Account (HSA) - Transportation benefits - Employee Assistance Program - Time Off/Leave (PTO, Vacation or Sick Leave)

Workplace Type

This is a fully onsite position in Detroit,MI.

Application Deadline

This position is anticipated to close on Jul 31, 2026.

About Actalent

Actalent is a global leader in engineering and sciences services and talent solutions. We help visionary companies advance their engineering and science initiatives through access to specialized experts who drive scale, innovation and speed to market. With a network of almost 20,000 consultants and 5,000 clients across the U.S., Canada, Asia and Europe, Actalent serves many of the Fortune 500. We are proud to be an Engineering News-Record (ENR) Top 500 Design Firm for our engineering design services and a ClearlyRated Best of Staffing® winner for both client and talent service.

The company is an equal opportunity employer and will consider all applications without regard to race, sex, age, color, religion, national origin, veteran status, disability, sexual orientation, gender identity, genetic information or any characteristic protected by law.

If you would like to request a reasonable accommodation, such as the modification or adjustment of the job application process or interviewing process due to a disability, please email View email address on click.appcast.io for other accommodation options.

San Francisco Fair Chance Ordinance: Pursuant to the San Francisco Fair Chance Ordinance, for all positions located in the city and county of San Francisco, we will consider for employment qualified applicants with arrest and conviction records.

Massachusetts Lie Detector: It is unlawful in Massachusetts to require or administer a lie detector test as a condition of employment or continued employment. An employer who violates this law shall be subject to criminal penalties and civil liability.

Use of Artificial Intelligence (AI): We may use Artificial Intelligence (AI) to support parts of our hiring process, including sourcing, screening, and evaluating candidates. AI helps assess applications and qualifications, but final decisions are made by our hiring team. By applying, you acknowledge and agree that your application may be reviewed using AI tools.