Senior Controls / Systems Engineer

Senior Controls / Systems Engineer

Mitsubishi PLC – Automotive Manufacturing Automation

Location: San Antonio, Texas

Position Summary

Our client is seeking an experienced Senior Controls / Systems Engineer with strong hands-on expertise in Mitsubishi PLC programming and industrial automation systems, particularly in automotive manufacturing environments.

The successful candidate will be responsible for control system design, PLC/HMI programming, troubleshooting, commissioning, and technical support for automated manufacturing equipment and production lines.

This position requires an engineer who can work independently, communicate directly with customers, and manage technical assignments from initial requirements through successful system implementation.

Key Responsibilities

1. Controls Engineering & Programming

Design, develop, modify, and troubleshoot PLC-based control systems for automated manufacturing equipment and production lines.

Develop and modify Mitsubishi PLC programs using GX Works2 and/or GX Works3.

Develop, configure, and troubleshoot Mitsubishi GOT/HMI applications.

Interpret and review electrical drawings, control schematics, I/O lists, and equipment specifications.

Integrate PLCs with sensors, drives, safety devices, barcode readers, vision systems, and other industrial equipment.

Configure and troubleshoot industrial communication networks, including CC-Link, Ethernet-based industrial networks, and DeviceNet.

2. Installation, Commissioning & Troubleshooting

Perform on-site installation support, commissioning, testing, debugging, and system verification.

Diagnose and resolve electrical, controls, and communication-related problems.

Support production line modifications, equipment upgrades, and system improvements.

Identify root causes of equipment failures and implement effective corrective actions.

Ensure compliance with applicable customer safety requirements and industrial electrical standards.

3. Project Execution & Customer Coordination

Communicate directly with customers to understand technical requirements, clarify specifications, and resolve engineering issues.

Independently manage assigned engineering tasks, schedules, and technical deliverables.

Coordinate with internal engineers, external vendors, and international engineering teams.

Prepare and maintain technical documentation, including PLC programs, electrical drawings, modification records, and commissioning reports.

Represent company professionally and independently at customer facilities.

Required Qualifications – Must Have

Technical Experience

Minimum 7 years of professional experience in industrial controls engineering, factory automation, or related fields.

Minimum 5 years of hands-on PLC programming and troubleshooting experience.

Demonstrated professional experience programming and modifying Mitsubishi PLCs, using GX Works2 and/or GX Works3.

Hands-on experience developing or modifying Mitsubishi GOT/HMI applications.

Practical experience with automated manufacturing equipment or production lines in the automotive industry.

Proven experience in on-site commissioning, equipment startup, and production troubleshooting.

Strong ability to read, interpret, and troubleshoot electrical schematics, control wiring, and PLC I/O systems.

Working knowledge of industrial communication networks, particularly CC-Link and industrial Ethernet.

Professional Capabilities

Ability to independently troubleshoot and resolve complex controls-related problems.

Experience communicating directly with customers regarding technical requirements and engineering issues.

Ability to manage assigned engineering activities with minimal supervision.

Strong problem-solving, organizational, and technical communication skills.

Ability to collaborate effectively with engineers and technical teams across different locations and countries.

Education

Bachelor's degree in Electrical Engineering, Controls Engineering, Mechatronics, Automation Engineering, or a related discipline, or equivalent relevant professional experience.

Travel & Work Requirements

Ability and willingness to travel domestically and internationally, including Japan and China, as required by project assignments.

Availability for extended on-site assignments, potentially lasting one to six months, depending on project requirements.

Flexibility to support occasional weekend, holiday, or nonstandard working hours when required for commissioning or production support.

Ability to meet applicable customer-site safety and security requirements.

Preferred Qualifications – Nice to Have

Experience with Allen-Bradley ControlLogix, Studio 5000, RSLogix, or Omron PLC systems.

Experience with automotive assembly, welding, body shop, or other automated production lines.

Experience integrating Keyence or Cognex vision systems and barcode readers.

Knowledge of industrial robotics and robot-to-PLC interfaces.

Familiarity with NEC, NFPA 70E, NFPA 79, and UL 508A, as applicable.

Experience using AutoCAD Electrical or similar engineering software.

Experience coordinating engineering activities with Japanese customers or international engineering teams.

Knowledge of Industry 4.0, IIoT, and manufacturing data integration systems.

Japanese language skills are a plus but not required.

Ideal Candidate Profile

The ideal candidate is a hands-on Senior Controls Engineer who:

Has substantial Mitsubishi PLC programming and troubleshooting experience.

Understands automotive manufacturing equipment and production line operations.

Can independently perform commissioning and resolve complex equipment issues.

Can communicate effectively with customers and take ownership of assigned technical work.

Is comfortable working in a small, internationally connected engineering organization where flexibility, accountability, and hands-on execution are essential.