Manufacturing Automation & Controls Engineer

Responsibilities

• Assist new products team with determining requirements and cost estimates for machines that are built in-house and by outside suppliers.
• Ensure compliance of the GSS, Watertown machine specification for new acquisitions and retrofits.
• Designs, develops, tests, sources, cost justifies, and installs various tools, devices, modifications, fixturing, machinery and equipment for production to increase safety, throughput, quality, capacity, and reliability.
• Manage the completion of those 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 support after launch.
• Cookordination with all levels of the organization to meet project timing and budget.
• Integrate vision inspection, process monitoring, servo control, mechanical inspections, and other devices or processes into new and existing equipment.
• Champion innovative techniques to improve manufacturing processes.
• Develop, debug, and validate control systems including electrical, PLC, hydraulic, pneumatic, servo, HMI’s, etc.
• Generate and implement standards and best practices – Logic, machine design, process, etc.
• Ensure that logic systems documentation is complete, up to date, stored in file structure, and available at all times.
• Provide general supervision to outside contractors (electrical, mechanical, PLC programming, etc.) to resolve material and/or equipment problems, research and implement upgrades, new tools and operating procedures.
• Work with Operators, Supervisors, Maintenance and QA department to improve processes and troubleshoot equipment repair and maintenance.
• Support diverse portfolio of processes and controls hardware.
• Ensure proper training and guidance is provided to GSS Production team.
• Apply Lean Mfg. / Toyota production system principles, IATF 16949, FMEA and Control plan concepts in controls engineering initiatives and tasks.
• Review existing logic programs to ensure safety of all associates and the processes are efficient & error proofed.
• Work closely with the Safety Team to ensure electrical controls and processes meet ergonomic and other safety standards.
• Champion continuous improvement projects to enhance safety, productivity, quality, reliability, capacity and processes.
• Project manage & coordinate implementation of continuous improvement actions.
• Ensures manufacturing practices are current, consistent, and compliant with GSS Policies and Procedures, all external state/federal regulations and customer requirements.
• Demonstrate a leadership mindset holding themselves and their team to high standards to ensure timely and successful project execution.
• Encourage working cross functionally and collaboratively.

Requirements

• BS Electrical, Mechatronics, Mechanical Engineering or equivalent
• Minimum of three years related to manufacturing experience in electrical, manufacturing, industrial engineering, or related field
• Experience in manufacturing, quality, safety and management is essential.
• 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, Data collection systems
• Diagnostic and troubleshooting skills
• Organizational and project management skills with the ability to prioritize and self-initiate when necessary
• Knowledge of tool design, gage design, and fixture design
• Computer skills include demonstrated knowledge of Microsoft office
• Working knowledge of plant/facilities engineering, electronics, pneumatics and engineering controls
• Excellent interpersonal, communication, organizational skills, and collaborative team player
• Broad-base knowledge of Lean Manufacturing, including 5s, Kaizen, Kanban, Poke-a-Yoke, Process Mapping & Value Stream Mapping, other tools & Techniques
• Strong analytical & problem-Solving Skills (Experience of proven techniques a plus ie. Shainin, DOE, 6 Sigma, 8D, 5 Why, etc.)
• Continuous Improvement mindset with ability to lead and influence others
• Mechatronics experience and interests
• Python, Visual Basic (VBA), Ignition!, IIOT, I4.0 are a plus
• Experience with Controls Systems including: DirectLogic PLCs (DirectSoft programming software) knowledge is a plus
• FANUC, ABB, and UR Robotics is a plus
• Cognex vision systems is a plus
• Equipment development, tooling design, gage design, CAD (NX, AutoCAD) 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