Controls Engineer

CONTROLS ENGINEER – SLITTING & BLANKING LINES

Company: Target Metal Blanking (TMB)

Department: Manufacturing

Reports To: Plant Manager

Location: New Boston, Michigan

Employment Type: Full-Time

Company Overview

Target Metal Blanking, part of the Target Steel family of companies, is a proud family-owned network of businesses, united by a shared commitment to excellence in steel processing, distribution, and logistics that services the U.S., Canada, and Mexico. With three facilities, and a team driven by honesty, integrity, and determination, we deliver tailored solutions to meet all our customers’ metal needs.

Position Summary

We are seeking an experienced Controls Engineer to design, program, troubleshoot, and maintain the automation and control systems for our slitting and blanking lines. This role is responsible for ensuring safe, reliable, and efficient operation of high-speed coil processing equipment, including slitters, blanking presses, shears, coil handling systems, and associated material handling automation. The ideal candidate has hands-on experience with PLC programming, motion control, and drive systems in a metal-forming or coil-processing environment.

Key Responsibilities

• Design, program, and commission PLC/HMI control systems for slitting lines, blanking lines, levelers, shears, and coil-processing equipment (uncoilers, recoilers, tensioners, loopers, feeders, presses).

• Develop and optimize motion control and synchronization logic for servo/VFD-driven axes (e.g., feed length, registration, tension control, knife positioning).

• Troubleshoot electrical, controls, and automation issues on the production floor to minimize downtime and maximize throughput.

• Maintain and improve control system architecture, including PLCs (Allen-Bradley/Rockwell, Siemens, etc.), HMIs, VFDs, servo drives, sensors, and safety systems.

• Collaborate with maintenance teams on new equipment installations, retrofits, and line upgrades.

• Implement and maintain machine safety systems (light curtains, e-stops, interlocks) in compliance with OSHA and ANSI standards.

• Develop and maintain electrical schematics, control narratives, and technical documentation for all controlled equipment.

• Support continuous improvement initiatives (OEE, cycle time reduction, scrap reduction) through data collection and control system enhancements.

• Program and integrate quality/gauging systems (thickness, width, camber, flatness monitoring) where applicable.

• Program, integrate, and maintain laser-based systems used in cutting, blanking, scribing, and measurement/gauging applications (e.g., laser cutting heads, laser distance/edge sensors, laser marking systems).

• Ensure proper interlocking, calibration, and safety compliance (Class 1–4 laser safety standards, IEC 60825, ANSI Z136) for laser-equipped equipment.

• Provide training and technical support to operators, maintenance technicians, and production staff on control system operation and basic troubleshooting.

• Participate in root cause analysis and corrective action for equipment failures and process deviations.

• Manage or support capital projects involving new slitting/blanking equipment, including vendor coordination, FAT/SAT testing, and startup.

• Maintain compliance with electrical codes (NEC/NFPA 79) and company safety standards.

• Provide on-call, off-shift, and other manufacturing site support as needed for critical production issues.

Required Qualifications

• Bachelor's degree in Electrical Engineering, Controls Engineering, Mechatronics, or related field (or equivalent combination of education and experience).

• 3+ years of controls engineering experience in a metal processing, coil handling, stamping, or high-speed manufacturing environment.

• Strong hands-on experience with PLC programming (Allen-Bradley RSLogix/Studio 5000, Siemens TIA Portal, or equivalent).

• Experience with HMI/SCADA development (FactoryTalk, WinCC, Ignition, or similar).

• Working knowledge of servo motion control, VFDs, and drive tuning (Allen-Bradley Kinetix, Siemens Sinamics, or similar).

• Solid understanding of electrical schematics, ladder logic, and industrial networking (EtherNet/IP, Profinet, DeviceNet).

• Familiarity with machine safety standards (NFPA 79, ANSI B11, OSHA) and safety PLC/relay systems.

• Experience integrating and troubleshooting laser cutting, laser gauging/measurement, or laser scribing systems and their control interfaces.

• Ability to read and interpret mechanical and electrical drawings.

• Strong troubleshooting skills with the ability to work under production pressure.

• Excellent communication skills and ability to work cross-functionally with operations, maintenance, and engineering teams.

Preferred Qualifications

• Direct experience with slitting lines, blanking presses, cut-to-length lines, or coil processing equipment specifically.

• Experience with tension control systems, loop control, and registration/feed systems.

• Familiarity with press controls, die protection systems, and progressive die feeding.

• Direct experience with laser cutting systems (fiber/CO2 laser heads) for blanking or trimming applications, including power/focus control and motion synchronization.

• Experience with laser-based gauging systems for width, edge detection, thickness, or profile measurement on coil lines.

• Experience with robotics or material handling automation integration.

• Knowledge of SPC/quality data systems and MES integration.

• Six Sigma, Lean Manufacturing, or continuous improvement certification.

Physical Requirements / Work Environment

• Ability to work on a manufacturing floor with exposure to moving machinery, noise, and varying temperatures.

• Ability to lift weight up to 50 lbs. occasionally.

• Ability to stand, walk, kneel, and climb as needed to access equipment and control panels.

• Availability for occasional evening/weekend work to support production schedules or emergency repairs.

What We Offer

• Competitive salary commensurate with experience

• Benefits: health/dental/vision, 401(k) match, PTO

• Opportunities for professional development and advancement

Target Metal Blanking (TMB) is an Equal Opportunity Employer.