Sr. Programmer Analyst

About the Role

The Sr. Programmer Analyst (Automation Controls Engineer / PLC/VFD Programmer) is a specialized role in industrial automation, focusing on designing, developing, implementing, and maintaining control systems for manufacturing, process industries, utilities, and machinery.

Responsibilities

• Design and develop PLC logic using languages such as Ladder Logic (LAD), Function Block Diagram (FBD), Structured Text (ST), and Sequential Function Chart (SFC) per IEC 61131-3 standards.
• Program and tune VFDs for motor speed, torque, and control applications.
• Integrate PLCs with HMIs (Human-Machine Interfaces), SCADA systems, sensors, actuators, servo drives, robotics, and other automation hardware.
• Configure industrial networks and protocols (e.g., EtherNet/IP, Modbus TCP, Profinet, OPC UA).
• Perform factory acceptance testing (FAT), site acceptance testing (SAT), functional testing, and on-site commissioning.
• Troubleshoot hardware/software issues in PLCs, VFDs, control panels, and I/O systems to minimize downtime.
• Monitor, debug, modify, and upgrade existing programs; implement process improvements, PID control loops, safety circuits, and efficiency enhancements.
• Back up programs and maintain documentation.
• Develop schematics, electrical drawings, P&IDs, and technical documentation.
• Work with cross-functional teams (engineering, maintenance, operations) and provide training/support to end-users.
• Ensure compliance with safety standards (e.g., NFPA 79, UL 508A) and regulations.
• Diagnose issues with motors, VFDs, instrumentation, and control logic using diagnostic tools and perform root-cause analysis.
• Write, test, troubleshoot, and optimize programs for Programmable Logic Controllers (PLCs) and integrate Variable Frequency Drives (VFDs) to control motors, machinery, and automated processes.
• Ensure systems run safely, efficiently, and reliably, often collaborating with electrical/mechanical engineers, technicians, and operations teams.
• Limited travel for commissioning, on-site troubleshooting, and support.
• Provide project and operational support as needed.

Requirements

• Bachelor’s degree in Electrical Engineering, Automation, Computer Science, Mechanical Engineering, or a related field (or equivalent vocational/technical training + experience).
• Typically 3–7+ years in PLC programming and industrial automation.

Skills

Soft Skills

• Strong problem-solving, analytical, and troubleshooting abilities.
• Communication and teamwork skills.
• Attention to detail.
• Willingness to travel and work in industrial environments.

Technical Skills

• Proficiency in major PLC platforms (e.g., Allen-Bradley/Rockwell Studio 5000/ControlLogix, Siemens TIA Portal/S7, Schneider, Beckhoff TwinCAT, Omron, Mitsubishi).
• Experience with VFDs (e.g., parameter configuration, tuning, integration with PLCs for brands like Allen-Bradley, Danfoss, Yaskawa, Siemens Sinamics).
• Knowledge of HMI/SCADA development (e.g., FactoryTalk View, Ignition, WinCC).
• Understanding of electrical schematics, motor controls, instrumentation, networking, and safety systems.

About the Company

Dauch Corporation is a premier Driveline and Metal Forming supplier serving the global automotive industry with a powertrain-agnostic product portfolio that supports electric, hybrid, and internal combustion vehicles. The company is headquartered in Detroit, MI, with operations that span 24 countries and more than 175 locations. Formed through the acquisition of Dowlais Group plc and its subsidiaries - GKN Automotive and GKN Powder Metallurgy, Dauch unites deep engineering roots with global manufacturing capabilities and an entrepreneurial spirit to move mobility forward.

www.dauch.com