Controls Engineer

Controls Engineer

This Controls Engineer role focuses on developing and deploying device-level analytics solutions for manufacturing operations. You will leverage PLC-based data collection and Python-based analytics to identify emerging equipment issues, reduce downtime, and enable proactive maintenance actions. The position centers on creating software applications that collect and analyze data from production equipment across multiple manufacturing plants, generating insights into throughput, efficiency, performance, and other key operational metrics.

Responsibilities

• Develop, test, and deploy PLC logic to collect critical operational data from manufacturing equipment while ensuring minimal disruption to production.
• Analyze, understand, and troubleshoot existing PLC programs and machine control logic to improve reliability and performance.
• Extract operational and diagnostic data from existing PLC programs and manufacturing systems to support device-level analytics.
• Modify, update, test, and deploy PLC code on live equipment, maintaining safe and continuous operations.
• Design, develop, validate, and standardize controls device data parsing PLC logic to support analytics and reporting.
• Own and update automated PLC logic generation tools to streamline deployment and configuration across multiple plants.
• Develop PLC logic for Rockwell, Siemens, and Fanuc platforms, integrating with programming languages such as Python and C++ where appropriate.
• Ensure compliance with common controls hardware and software strategies when implementing new device-level analytics controls solutions.
• Ensure adherence to plant floor systems, networking, and cybersecurity requirements in all controls and analytics implementations.
• Collaborate with core analytics teams, business stakeholders, IT, automation specialists, and the broader analytics community to capture requirements, prioritize initiatives, and plan deployments.
• Support controls, networks, and IT architects in developing and testing necessary controls software and integrating device-level analytics logic into core PLC templates.
• Create and maintain training documents, standardized work instructions, and reference materials to support consistent implementation and knowledge transfer.
• Monitor and understand the latest industry trends in advanced analytics tools and explore opportunities to apply them in manufacturing environments.
• Review observations from manufacturing plants, propose improvement solutions, and provide feedback to enhance device-level analytics strategies.
• Provide training, guidance, and support to controls execution teams, strategic suppliers, and plant personnel as needed during deployments and upgrades.
• Travel to manufacturing facilities on an as-needed basis to support pilots, testing, training, upgrades, and commissioning of analytics and controls solutions.
• Connect Python-based analytics solutions to plant equipment, validate data collection processes, and ensure successful implementation within production environments.

Essential Skills

• 2+ years of experience in industrial automation, controls engineering, or manufacturing automation.
• Experience working in automotive powertrain manufacturing environments such as propulsion systems facilities, engine plants, or similar operations.
• Strong hands-on PLC programming experience, including Siemens PLC programming using STEP 7 and TIA Portal.
• Experience with Rockwell Automation (Allen-Bradley) PLCs, including troubleshooting and debugging.
• At least 1 year of Allen-Bradley PLC experience, which may include academic or project-based work.
• Intermediate-level Python programming skills, including data extraction, data analysis, and automation scripting.
• Demonstrated ability to develop, modify, and deploy PLC logic on live production equipment.
• Ability to travel as needed to manufacturing plants across the United States.
• Ability to work primarily from a technical center location while coordinating activities with multiple plant sites.

Additional Skills & Qualifications

• Experience in automotive OEM or Tier-1 supplier environments.
• Experience working with automation integrators such as GROB, KUKA, Comau, or Valiant.
• Familiarity…