Sr. Engineer, Electrical & Controls

Job Overview

The Electrical & Controls Engineer is responsible for supporting, designing, and improving electrical and automated control systems within a highly automated automotive manufacturing facility. This role combines project planning, system implementation, hands‑on troubleshooting, and technical training to maintain high equipment reliability and production efficiency.

• Design, program, maintain, and improve PLC-based control systems used in automated manufacturing processes.
• Support and optimize robotic systems, automated assembly lines, material handling equipment, and process automation.
• Develop and maintain electrical schematics, PLC documentation, and control system standards.
• Integrate new equipment and automation technologies into existing production systems.
• Ensure compliance with plant automation standards and electrical codes.

• Plan and lead electrical and automation projects including equipment upgrades, line modifications, and new production installations.
• Support equipment launches and production line startups.
• Work with vendors, integrators, and contractors to implement automation solutions.
• Establish and manage project timelines and budgets, providing timely updates to management.

• Provide hands‑on troubleshooting of electrical and automation issues affecting production.
• Diagnose and resolve problems with PLC programs, robotics systems, HMI systems, sensors, vision systems, servo drives, VFDs, and industrial networks.
• Work with maintenance technicians to restore equipment functionality during production downtime.
• Conduct root cause analysis of equipment failures and implement permanent corrective solutions.

• Support robotic systems used in production and material handling operations.
• Troubleshoot robot communication with PLCs and automation equipment.
• Assist with robot programming, system adjustments, and integration with automated cells.
• Support safety systems including light curtains, safety PLCs, and interlock circuits.

• Train maintenance technicians on electrical troubleshooting, PLC diagnostics, and automation systems.
• Develop training materials and technical documentation for automated equipment.
• Mentor technicians to improve their understanding of robotics, sensors, and control systems.
• Promote best practices in electrical safety and automation maintenance.

• Promote and enforce a safety‑first culture, ensuring adherence to safety guidelines, procedures, and regulations.
• Implement and maintain stringent environmental practices that align with relevant standards and regulations.

• Establish and maintain robust quality control processes for maintenance activities.
• Collaborate closely with Quality Assurance teams to identify opportunities for quality enhancement.

• Coordinate maintenance schedules to minimize disruption to production activities and meet production goals.
• Prioritize maintenance tasks based on criticality to ensure on‑time completion and optimal equipment availability.
• Monitor performance metrics to optimize maintenance delivery, meet key performance indicators, and ensure timely completion.

• Identify opportunities for productivity improvement within the maintenance department.
• Implement measures to increase efficiency, reduce downtime, and optimize resource utilization.
• Collaborate actively with cross‑functional teams to drive continuous improvement initiatives.

• Prepare regular comprehensive reports on maintenance activities, performance metrics, and improvement initiatives.
• Provide valuable insights to the Site Head and senior management.

• Experience with PLC programming (Allen‑Bradley, Siemens, or similar).
• Experience with HMIs, VFDs, motion control, and industrial communication networks.
• Strong troubleshooting experience in manufacturing environments.

• Industrial networks (Ether Net/IP, Modbus, Profinet, etc.)
• Electrical schematics and control panel design
• Robotics or automated manufacturing systems (preferred)
• Root…