Controls Engineer

Job Title:

Controls Engineer Job Description

The Controls Engineer will support the rapid growth of a new Greenfield facility focused on advanced electric vehicle power module production. This role sits within the regional product engineering group for xEV products and is responsible for establishing and optimizing equipment, processes, and quotations for Intelligent Power Module (IPM) programs used in inverters. The position focuses heavily on automated optical inspection and vision systems for power module assembly, along with failure mode analysis and judgment methods, while driving best practices, cost efficiency, and synergies across multiple xEV programs.

• Support the safe launch of Intelligent Power Module (IPM) products and associated manufacturing processes, ensuring robust controls and reliable production performance.

• Support the development of technology, resources, and production requirements for power module programs, including specification and implementation of capital equipment and automation solutions.

• Contribute to new IPM business opportunities by providing technical input on process capability, equipment needs, and inspection strategies for inverter power modules.

• Support production process and equipment issues by diagnosing root causes, developing corrective actions, and implementing sustainable solutions in a manufacturing environment.

• Establish and refine automated optical inspection and vision (camera) inspection systems for power module assembly, including definition of pass/fail criteria and judgment methods.

• Identify and leverage synergies across programs and products by sharing best practices, standardizing processes where possible, and driving cost-efficient solutions across xEV activities.

• Interface directly with inspection equipment and automation controls to configure, modify, and implement inspection criteria, pass/fail thresholds, and other operational parameters or programs.

• Collaborate with cross-functional teams in project management activities, including capital equipment planning, project engineering tasks, and coordination of installation and commissioning.

• Apply automotive and electronics manufacturing methodologies such as APQP, FMEA, and control plans to ensure robust process design and ongoing process control.

• Contribute to failure mode analysis and implement corrective actions to improve product quality and process reliability in electronics and electromechanical systems.

• Prepare and present clear technical information, reports, and recommendations to various levels of associates, management, and customers in both verbal and written formats.

• Lead and mentor other engineers or team members in controls, inspection processes, and continuous improvement initiatives across the organization.

• Manage multiple projects and deadlines simultaneously while maintaining strong organization, attention to detail, and alignment with corporate objectives.

• Perform other duties as assigned to support corporate objectives and the continued growth and expansion of the facility.

• Bachelors degree in Engineering.

• At least 5 years of controls engineering experience in a manufacturing environment, preferably within the automotive industry.

• Strong controls engineering background in automation and electromechanical systems.

• Proficiency with vision systems used in automated inspection, specifically including Cognex and Keyence platforms.

• Experience with project management and project engineering in a manufacturing setting, including capital equipment (capex) planning and implementation.

• Knowledge of PLC programming and automation controls for manufacturing equipment.

• Familiarity with robotics integration, such as systems from Fanuc or similar industrial robot platforms.

• Experience working in or supporting the automotive industry and Tier 1 supplier environments.

• Ability to diagnose and resolve production process and equipment problems in a high-volume manufacturing environment.

• Strong communication skills, with the ability to prepare and present technical information clearly to diverse audiences.

• Ability to lead and mentor engineers or team members in controls and inspection-related activities.

• Well-developed organizational skills and attention to detail, with the ability to manage multiple concurrent projects and deadlines.

• Work experience in electronics manufacturing environments, with emphasis on inspection processes, inspection equipment, and development of…