Controller Engineer

Job Description AESC is looking to add a Controller Engineer to our team in Smyrna, TN. Full-Time On-site About AESC US LLC AESC is an exciting, newly created global organization committed to solving the challenges of a sustainable future and becoming the leading supplier of full-value-chain battery solutions. Our lithium-ion batteries can be found in nearly one million electric vehicles worldwide and have a stellar safety record of zero-critical issues. AESC US is leading the way in battery technology. We design and manufacture EV battery technology for various electric vehicles and equipment. We are working hard towards unlocking the full potential of sustainable energy and climate change mitigation. We will continue to build upon our successes and expand into new markets and industries, producing innovative and competitive products and technologies that advance the goal of a zero-carbon emission future. AESC is headquartered in Japan and has battery manufacturing locations in Japan, UK, China, and the U.S. AESC Mission Our mission is to solve the challenges for a sustainable future. Together, we can make a meaningful impact. About the Role What You Will Do Manufacturing Process Implementation: Lead the implementation and launch of all manufacturing processes to production readiness and support post-SOP (Start of Production). Equipment Installation and Commissioning: Install, commission, and qualify new equipment and tooling in collaboration with vendors and internal teams to ensure seamless production integration. Continuous Improvement: Utilize root cause analysis, Design of Experiments (DOE), and other methodologies to achieve and enhance process capabilities. Documentation and Training: Develop and maintain process documents such as Work Instructions (WI) and conduct training for production employees, including technicians, team leaders, and maintenance personnel. Failure Mode and Effects Analysis (FMEA): Own the FMEA process for your assigned area, documenting lessons learned and driving continuous improvement initiatives. Controls Engineering Integration: Ensure robust integration between equipment controls and site MES/SCADA systems, collaborating with facility design teams for optimized control system compatibility. Control Systems Development: Design and develop PLC/HMI control systems, motion control, robotics, and sensors to automate manufacturing processes, including material handling, assembly, testing, and packaging. Control Systems and Protocols: Familiarity with protocols such as Profinet, ModbusTCP, Ethernet/IP, BACnet, OPC. Proficiency in programming languages used in PLC-controlled facilities: Structured Text, Ladder Logic, Function Block Diagram, Sequential Function Chart (SFC), IEC 61131-3 Standard, JSON. Programming: Responsible for the design, implementation, and lifecycle ownership of structured, maintainable control software for high-volume battery manufacturing equipment. This role sets and enforces structured programming standards, with a strong emphasis on IEC 61131-3 Structured Text (ST) to ensure safe, scalable, and supportable automation systems. SCADA/HMI Development: Work with the team to develop standard HMI and SCADA designs using Ignition by Inductive Automation. Instrumentation: Assist process engineers with selecting and placing instrumentation, including air particle sensors, flow, pressure, and temperature sensors. Automation and Standardization: Select and integrate automation components such as PLCs, HMIs, drives, sensors, and robotics. Standardize and optimize control system architectures and logic. Troubleshooting and Optimization: Lead troubleshooting and continuous improvement initiatives to enhance equipment effectiveness and process automation. Leadership: Exhibit strong leadership qualities by guiding team members, fostering a collaborative and innovative work culture, and solving challenges with a forward-thinking mindset. Complete other duties as assigned. Qualifications What You Need Education: Bachelor’s degree in electrical, Controls, Mechatronics Engineering, or a related field. Experience: Minimum of 5 years of experience in controls engineering or process/manufacturing engineering, ideally within the automotive or battery manufacturing sectors. Technical Expertise: Proficiency in PLC/HMI programming (e.g., Siemens, Rockwell Automation), control systems integration, and automation component selection. Software Skills: Proficiency in Microsoft Office Suite (Word, Excel, PowerPoint), CAD, Minitab, and data analysis tools. Advanced skills in control system development environments such as Siemens Step 7, Studio 5000, or equivalent. Problem-Solving Skills: Strong analytical and troubleshooting abilities, with experience in root cause analysis, DOE, FMEA, and 8D methodologies. Communication and Leadership: Excellent interpersonal and communication skills, with the ability to lead cross-functional teams and collaborate effectively across departments and cultural boundaries. Global Perspective: Willingness and ability to travel up to 25%, including overseas travel to vendors and sister locations in China, South Korea, or Japan during the industrialization phase. Understands and follows all standards of IATF16949 and VDA 6.3 quality standards. (training and awareness will be provided for those who are not familiar with these standards) Understands and follows all standards of ISO14001 environmental standards. (training and awareness will be provided for those who are not familiar with these standards) Nice to Have Advanced Education: Master’s degree in a related engineering field. Industry Experience: Experience in high-volume automotive launch and production environments with a focus on lean manufacturing and continuous improvement. Professional Certifications: Relevant certifications in automation and control systems, such as Certified Automation Professional (CAP). Startup Experience: Proven experience in startup environments, particularly in the setup, installation, and commissioning of new manufacturing facilities. Skilled in establishing and implementing cleanroom standards and contamination control protocols, ensuring that all equipment and processes comply with stringent cleanliness and operational requirements in new facility settings. Industry Knowledge: Strong expertise in industries requiring precise control and maintenance of equipment within controlled environments, such as battery manufacturing, automotive, electronics, or pharmaceuticals. Familiarity with the challenges associated with maintaining high standards of equipment reliability, process efficiency, and cleanliness in these specialized sectors. Multilingual Proficiency: Fluency in Mandarin or other foreign languages is advantageous. Cross-Cultural Experience: Experience working in a global organization and understanding of cross-cultural business practices. What We Offer An inclusive and diverse work environment that fosters and encourages professional and personal development. Highly automated, clean, safe, and temperature-controlled production environment Medical, Dental and Vision Insurance HSA and Flexible Spending Accounts 401K with company match Life Insurance (Company paid and additional voluntary life available) Paid Vacation and 14 Paid Holidays Short term and long-term disability coverage (Company Paid) Tuition reimbursement Equal Employment Opportunity At AESC, we are committed to providing Equal Employment Opportunity (EEO) to all individuals. We participate in E-Verify and will provide the federal government with your Form I-9 information to confirm that you are authorized to work in the U.S. Join us in our passion to design, manufacture, and sell high-performance products, contributing to a sustainable and zero-carbon emission future. Physical Requirements Ability to sit for extended periods of time. Ability to read, write, speak, hear; stand; walk; use hands to finger, handle, or feel; reach and lift with hands and arms frequently throughout the day. Required to occasionally lift, push, pull and/or move up to 10 pounds and occasionally required to lift, push, pull and/or move up to 35 pounds. Travel First year not to exceed 75% domestic travel and may include international travel. From the second year up to 25% travel. Extensive travel abroad when assigned to coordinate a major program. Ability to travel to supplier locations on short notice. Work Environment The work environment is primarily an automated manufacturing plant with a concrete floor and is characterized by some temperature extremes, moderate noise, and forklift traffic. The individual must be able to perform all essential functions as appropriate on the plant floor, in meetings, and with employees, management, customers and suppliers. Candidate must perform the essential duties and responsibilities with or without reasonable accommodation efficiently and accurately, and without causing significant safety threat to self or others. The statements made herein are intended to describe the general nature and level of work being performed by employees assigned to this job classification. They are not intended to be construed as an exhaustive and inclusive list of all responsibilities, duties, and/or skills required of personnel so classified. #J-18808-Ljbffr AESC