Controls & Process Engineering Technician

Job Description

Position Summary:

Under the direction of the Engineering Leadership team, the Engineering Technician – Controls & Process supports manufacturing operations by maintaining, troubleshooting, and improving production equipment and processes. This role is responsible for machine controls, PLC diagnostics, electrical systems, and infrastructure equipment, while also supporting process improvements, documentation, data analysis, and engineering projects. The position requires close collaboration with Engineering, Maintenance, Production, and external vendors to ensure safe, efficient, and reliable manufacturing operations.

Responsibilities of Position:

1. Troubleshoot, diagnose, and resolve control system hardware, software, and I/O device issues.
2. Program, modify, and maintain PLC-controlled equipment (new and existing machines).
3. Troubleshoot and repair production equipment, including electrical, hydraulic, and pneumatic systems.
4. Diagnose and resolve high-voltage electrical circuit issues (220–440 VAC).
5. Support engineering projects including equipment improvements, line projects, installation, debug, and startup.
6. Work with production associates to analyze equipment malfunctions and performance inconsistencies.
7. Collect and analyze data for engineering projects, COPQ, downtime reduction, and process improvements.
8. Support implementation and verification of corrective actions.
9. Assist with tooling prints, fixture development, and coordination with vendors, Maintenance, and the Tool Room.
10. Create, update, and maintain machine files, schematics, and engineering documentation.
11. Develop and support Work Instructions, Visual Aids, Alerts, Process Trial Reports, Gauge Procedures, and development reports.
12. Evaluate suitability of electrical, pneumatic, and mechanical components for plant applications.
13. Support continuous improvement initiatives including poka-yoke, scrap reduction, robustness, and ease of manufacturing.
14. Communicate effectively with production under time-sensitive and high-pressure situations.
15. Maintain a positive work environment through professional interaction with co-workers, supervisors, vendors, and visitors.
16. Work across shifts and off shifts as required.
17. Perform other duties as assigned by Engineering or Maintenance leadership.

Skill Requirements:

1. Regular and predictable attendance.
2. Strong troubleshooting, problem-solving, and analytical skills.
3. Minimum of 5 years' experience diagnosing and programming PLC systems (Omron, Siemens, and Allen Bradley preferred).
4. Working knowledge of IATF 16949 and core tools (SPC, APQP, PFMEA, MSA).
5. Ability to read and interpret electrical, pneumatic, hydraulic, and mechanical schematics and blueprints.
6. Proficient computer skills using Microsoft Office (Outlook, Excel, PowerPoint).
7. Ability to use laptops for system diagnostics and equipment interfaces.
8. Strong written and verbal communication skills.
9. Highly organized, self-motivated, and able to work independently or within a team environment.
10. Familiarity with OSHA safety standards and safe work practices.
11. Ability to use hand tools and standard shop equipment.
12. Mechanical and electrical aptitude.

Education and Experience Requirements:

1. High School Diploma or GED required.
2. Two-year degree, technical certificate, or equivalent experience in Industrial Electronics, Mechatronics, Electrical, Mechanical, Manufacturing, or Engineering-related fields preferred.
3. Minimum 5 years' experience in a manufacturing or automotive production environment.
4. Experience with extrusion technologies, tooling, or machine design preferred.

Licensing or Special Certification Requirements:

1. Ability to obtain and maintain company-provided Crane Certification.
2. Additional plant-specific or technical certifications are a plus.

Physical Requirements:

1. Walking, standing, bending for extended periods.
2. Sitting for periods up to 4 hours; standing/walking up to 6 hours.
3. Lifting, pushing, and pulling up to 50 lbs.
4. Ability to wear required PPE including hearing protection, safety glasses, steel-toe shoes, and specialized PPE as required.

Working Conditions:

1. Work performed within an automotive component manufacturing facility and office setting.
2. Exposure to heat, cold, dust, fumes, and chemicals.
3. Temperature ranges from approximately 65°F to 105°F depending on season and area.
4. Noise levels may reach 85 dB or higher in certain production areas.