Controls Engineer

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.