Senior Controls Engineer

Position Summary

The Senior Controls Engineer is responsible for the design, development, implementation, and optimization of manufacturing control systems and automation solutions supporting automotive production operations. This role leads capital equipment projects from concept through launch, ensuring processes meet safety, quality, productivity, scrap, and labor objectives. The Senior Controls Engineer serves as a technical expert in PLC programming, robotics integration, process controls, and continuous improvement initiatives. This position also supports new product launches, equipment upgrades, troubleshooting, and plant automation strategies. This scope aligns with the existing IAC role description, which includes managing capital equipment processes, establishing controls, documenting processes, participating in PFMEA activities, and leading continuous improvement efforts.

Essential Responsibilities

• Lead the design, programming, commissioning, and validation of automated manufacturing equipment and control systems.
• Develop and modify PLC, HMI, servo, vision, and robotic control programs.
• Support new program launches by ensuring all controls systems meet project timing, quality, and production requirements.
• Establish process parameters, equipment controls, and monitoring systems to maintain product quality and operational performance.
• Troubleshoot and resolve electrical, controls, automation, and process-related issues.
• Collaborate with manufacturing, quality, maintenance, product engineering, and suppliers to improve equipment performance and process capability.
• Lead root cause analysis and corrective actions for equipment downtime and quality concerns.
• Develop and maintain controls documentation including:
  • Electrical schematics
  • Network architecture
  • PLC/HMI backups
  • Process control plans
  • Equipment standards
• Participate in PFMEA and manufacturing feasibility reviews.
• Support capital equipment sourcing, installation, validation, and startup activities.
• Train maintenance and production personnel on equipment operation, troubleshooting, and preventive maintenance.
• Drive continuous improvement initiatives focused on:
  • OEE improvement
  • Scrap reduction
  • Cycle-time reduction
  • Cost savings
  • Automation expansion
• Ensure compliance with all safety, environmental, and customer requirements.

Education

• Bachelor's Degree in Electrical Engineering, Controls Engineering, Mechatronics Engineering, or related technical field.

Experience

• 7-10 years of controls engineering experience in a manufacturing environment.
• Automotive Tier 1 supplier experience strongly preferred.
• Experience supporting automated assembly, injection molding, foam, or interior trim manufacturing processes preferred.

Technical Skills

• PLC Programming:
  • Allen-Bradley
  • Siemens
  • Rockwell
• Programming remote IO using remote blocks:
  • Rockwell/Balluff
• Industrial Robotics:
  • FANUC
  • ABB
• Industrial Networks:
  • EtherNet/IP
  • Profibus/Serial
  • IO Link
• Electrical controls design and troubleshooting
• Safety systems and machine safeguarding
• Dynamic Robotic Pathing
• Cybersecurity for OT Environments
• Knowledge in how to safety deploy/manage NAT VPN Setup for Tooling Machines
• Allen-Bradley ControlLogix/CompactLogix, Siemens S7/TIA Portal, Beckhoff TwinCAT; structured programming, sequencing, interlocks, and fault recovery
• AMRs/AGCs
• Vidi Cognex Vision
• Simulation and virtual commissioning: Digital twins, PLC simulation, robot simulation, and offline commissioning.
• MES Traceability
• Python, C#, C++, or JavaScript
• SQL, REST APIs, MQTT, OPC UA, and historian connectivity
• Euromap Data Transfer
• Ignition
• PowerBI

Competencies

• Strong project management skills
• Excellent analytical and troubleshooting abilities
• Ability to lead cross-functional teams
• Effective written and verbal communication
• Customer-focused mindset
• Continuous improvement orientation
• Ability to manage multiple projects simultaneously

Physical Requirements

• Ability to work in manufacturing and production environments.
• Occasional lifting of up to 25 pounds.
• Ability to travel to plants, suppliers, and customer locations as required.

Preferred Qualifications

• Professional Engineer (PE) certification
• Certified Automation Professional (CAP)
• Experience with Industry 4.0 technologies, IIoT, and advanced manufacturing systems
• Experience supporting global manufacturing launches

Key Performance Indicators (KPIs)

• Equipment uptime/OEE
• Launch timing performance
• Scrap reduction
• Process capability improvements
• Safety performance
• Automation project completion
• Manufacturing cost reductions