Manufacturing Automation & Controls Engineer

Global Steering Systems, LLC (“GSS”), a subsidiary of Neapco, is a high-volume global manufacturer of automotive components, primarily steering columns. We supply our products to the world’s leading auto manufacturers. With international manufacturing facilities in China and Poland, we have over 300 employees working in our 180,000-square-foot Watertown location. Our global business is built on a foundation of commitment to our team, customers, and core values of safety, performance, sustainability, and responsibility.

About the role

This position provides a combination of manufacturing engineering and electrical controls engineering services for new production equipment and all aspects of manufacturing to ensure world-class products are available to our customers. The role involves working independently with minimal supervision, relying on experience and strong organizational skills. This specialist will collaborate with all levels of the organization to improve efficiency, fix programming and mechanical issues, and reduce equipment downtime. The work impacts equipment, employees, work environment, and process standards.

Responsibilities

• Assist the new products team with determining requirements and cost estimates for machines built in-house and by outside suppliers.
• Ensure compliance with GSS Watertown machine specifications for new acquisitions and retrofits.
• Design, develop, test, source, cost-justify, and install tools, devices, modifications, fixturing, machinery, and equipment to increase safety, throughput, quality, capacity, and reliability.
• Manage projects from conception through evaluation, justification, purchase, and implementation.
• Lead projects, create timing plans, design control systems, create schematics, order components, write programs, debug machines, and provide post-launch support.
• Coordinate with all organizational levels to meet project timing and budget.
• Integrate vision inspection, process monitoring, servo control, mechanical inspections, and other devices into new and existing equipment.
• Champion innovative techniques to improve manufacturing processes.
• Develop, debug, and validate control systems including electrical, PLC, hydraulic, pneumatic, servo, and HMIs.
• Generate and implement standards and best practices for logic, machine design, and processes.
• Ensure logic systems documentation is complete, up-to-date, and accessible.
• Supervise outside contractors (electrical, mechanical, PLC programming) to resolve equipment issues, research upgrades, and implement new tools or procedures.
• Collaborate with Operators, Supervisors, Maintenance, and QA to improve processes and troubleshoot equipment repair and maintenance.
• Support a diverse portfolio of processes and controls hardware.
• Provide training and guidance to the GSS Production team.
• Apply Lean Manufacturing, Toyota Production System principles, IATF 16949, FMEA, and Control Plan concepts in controls engineering initiatives.
• Review existing logic programs to ensure safety and efficiency, and error-proof processes.
• Work closely with the Safety Team to ensure electrical controls and processes meet ergonomic and safety standards.
• Champion continuous improvement projects to enhance safety, productivity, quality, reliability, capacity, and processes.
• Project manage and coordinate implementation of continuous improvement actions.
• Ensure manufacturing practices are current, consistent, and compliant with GSS policies, external regulations, and customer requirements.
• Demonstrate leadership, holding themselves and their team to high standards for timely and successful project execution while encouraging cross-functional collaboration.

Requirements

• BS in Electrical, Mechatronics, Mechanical Engineering, or equivalent.
• Minimum of three years of manufacturing experience in electrical, manufacturing, industrial engineering, or a related field.

Skills

• Experience with Controls Systems, including:
  • Allen Bradley PLCs, Kinetix Motion Controls (Studio 5000 programming software), and HMIs (FactoryTalk Studio).
  • GE PLCs (Proficy Machine Edition software).
  • Siemens PLCs.
  • Robotics.
• Knowledge of ladder logic programming, SQL, database structure, and data collection systems.
• Diagnostic and troubleshooting skills.
• Organizational and project management skills with the ability to prioritize and self-initiate.
• Knowledge of tool design, gage design, and fixture design.
• Proficiency in Microsoft Office.
• Working knowledge of plant/facilities engineering, electronics, pneumatics, and engineering controls.
• Excellent interpersonal, communication, organizational skills, and a collaborative team-player mindset.
• Broad knowledge of Lean Manufacturing, including 5S, Kaizen, Kanban, Poka-Yoke, Process Mapping, and Value Stream Mapping.
• Strong analytical and problem-solving skills (experience with Shainin, DOE, 6 Sigma, 8D, 5 Why, etc., is a plus).
• Continuous improvement mindset with the ability to lead and influence others.
• Mechatronics experience and interests.
• Python, Visual Basic (VBA), Ignition!, IIOT, and Industry 4.0 knowledge are a plus.
• Experience with DirectLogic PLCs (DirectSoft programming software) is a plus.
• FANUC, ABB, and UR Robotics experience is a plus.
• Cognex vision systems experience is a plus.
• Equipment development, tooling design, gage design, and CAD (NX, AutoCAD) experience is a strong plus.
• ISO 14001 and IATF 16949 experience is a strong plus.
• Knowledge of Automotive AIAG Core tools (FMEA, Control Plan, PPAP, MSA, SPC) is a strong plus.

Additional Notes

• Able to lift up to 35 pounds.
• Ability and willingness to travel internationally.
• Able to work staggered or 2nd shift when necessary.
• Relocation assistance not provided.
• Applicants must be authorized to work in the United States; visa sponsorship is not available.