Controls Engineer

Controls Engineer

The Controls Engineer will support integration and commissioning activities for a high-volume automotive manufacturing facility in northern Indiana. In this role, you will focus on PLC integration and commissioning using Allen-Bradley Studio
5000, HMI development and debugging using Allen-Bradley Factory Talk View, and implementation of safety communications and logic. You will work closely with robot programmers to validate functionality between PLCs and robots in an automotive bodyshop environment, ensuring that robotics, roller beds, conveyors, and other automated equipment operate reliably and efficiently throughout launch and ramp-up.

• Support PLC integration and commissioning activities for a high-volume automotive manufacturing line.
• Program, configure, and commission Allen-Bradley PLCs using Studio
  5000, including online modifications and system updates.
• Develop, configure, and debug HMIs using Allen-Bradley Factory Talk View to support operator interfaces and system monitoring.
• Implement and validate safety communications and safety logic in accordance with Rockwell safety standards and project requirements.
• Interface directly with robot programmers to validate and refine communication and functionality between the PLC and robots within the bodyshop environment.
• Work with automated equipment such as robotics, roller beds, conveyors, and related systems to ensure proper control, interlocking, and sequencing.
• Execute dry cycles and run full system tests to verify proper operation of the integrated equipment and control systems.
• Perform detailed system debugging and troubleshooting of PLC, HMI, and safety logic issues, resolving faults and optimizing system performance.
• Support pre-commissioning activities, including testing of special means builds, pilot vehicles, and early production runs.
• Collaborate with other PLC programmers and engineering staff to standardize solutions, share best practices, and maintain consistent control strategies.
• Document changes, configurations, and test results to support traceability, knowledge transfer, and long-term system support.
• Follow established automotive manufacturing and plant standards while adapting to evolving project requirements during launch.

• Minimum of 3 years of experience with PLC commissioning in an industrial automation environment.
• Hands‑on experience with Allen‑Bradley Studio
  5000 (PLC) for programming, integration, and commissioning.
• Hands‑on experience with Allen‑Bradley Factory Talk View (HMI) for HMI development and debugging.
• Strong background in automation and controls engineering, including PLC programming, HMI configuration, and troubleshooting.
• Experience working with Allen‑Bradley PLC platforms and Rockwell Automation technologies.
• Ability to troubleshoot and resolve controls‑related issues involving PLCs, HMIs, safety systems, and field devices.
• Ability to work onsite in Warsaw, Indiana, six days per week on a 12‑hour shift schedule.
• Experience collaborating with robot programmers or working in environments where PLCs interface with robotics.
• Strong problem‑solving skills and the ability to work effectively in a fast‑paced, launch‑focused manufacturing setting.

• Experience with Stellantis manufacturing standards is a strong plus.
• Prior bodyshop experience in an automotive manufacturing environment is highly desirable.
• Familiarity with Rockwell Safety systems and safety communication architectures.
• Experience working on large‑scale PLC integration and commissioning projects.
• Background supporting special means builds, pilot vehicles, or pre‑commissioning activities in automotive or similar industries.
• Ability to collaborate within a multi‑disciplinary engineering team and communicate effectively with peers and leadership.

This role is fully onsite at a new automotive manufacturing facility in Warsaw, Indiana. The project is planned to run through early November 2026. The position follows a single 12‑hour shift schedule, six days per week, reflecting the intensity of a major automotive launch. You will work alongside a team of PLC programmers and…