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 & Education

• 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.

• 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.