Position Summary
The Controls Engineer is responsible for the design, development, implementation, and continuous improvement of automation and control systems within a high-volume automotive interior manufacturing environment. This role plays a critical part in ensuring equipment reliability, production efficiency, safety compliance, and overall manufacturing excellence through advanced programming, troubleshooting, and system optimization.
Key Responsibilities
Automation & Controls Engineering
- Design, program, and troubleshoot PLC and HMI systems, primarily using Allen-Bradley platforms (SLC 500, MicroLogix, CompactLogix, PanelView).
- Develop and support industrial communication networks (Ethernet/IP, DH+, DH-485, RS-232).
- Integrate and support advanced manufacturing technologies including robotics, vision systems, servo systems, and MES connectivity.
- Maintain and update electrical schematics using AutoCAD.
Equipment & Production Support
- Provide hands-on technical support to production and maintenance teams to minimize downtime and improve equipment performance.
- Diagnose and resolve electrical and controls-related issues, including AC/DC circuits, sensors (PNP/NPN), and industrial networks.
- Support new equipment installation, commissioning, and machine buyoffs to ensure compliance with plant standards and specifications.
Continuous Improvement
- Lead and participate in continuous improvement initiatives focused on:
- Cycle time reduction
- Equipment uptime and reliability
- Quality enhancement and error-proofing (Poka-Yoke)
- Identify and implement new technologies to improve manufacturing efficiency and product quality.
Project & Launch Support
- Participate in equipment quoting, design reviews, and vendor selection to ensure cost-effective and standardized solutions.
- Support new product and equipment launches, ensuring adherence to safety standards and operational readiness.
- Manage multiple projects and priorities in a fast-paced manufacturing environment.
Training & Documentation
- Train maintenance and operations personnel on new equipment, technologies, and troubleshooting techniques.
- Maintain and update plant-wide controls standards and documentation.
- Establish and manage electrical spare parts inventory (crib stock).
- Experience with AC Power from 480VAC 3? to 110Vac, and 24 VDC Control circuits
Education & Experience
- Automotive interior or Tier 1 supplier experience preferred.
- Bachelor’s degree in electrical engineering or related field preferred.
- Minimum of 5 years of controls engineering experience in a manufacturing environment
- Experience with fully automated assembly systems featuring integrated Poka-Yoke and MES.
- Demonstrated success implementing new automation technologies into existing production lines.
- Experience with automated assembly systems; injection molding experience is a strong plus.
Technical Expertise
- Strong knowledge of PLC programming and HMI development
- Working knowledge of pneumatics and hydraulics.
- Experience with:
- Robotics (Fanuc, ABB preferred
- Vision systems (Keyence, Cognex)
- MES integration
- DC torque tool interfaces
- Proficiency in electrical troubleshooting across:
- 480VAC 3-phase systems
- 110VAC systems
- 24VDC control circuits
Additional Skills
- Ability to manage multiple projects and priorities effectively.
- Experience with machine buyoff procedures and equipment validation.
- Strong communication and collaboration skills across all organizational levels.
- Proficiency with Microsoft Office applications.
