Controls Engineer

Controls Engineer

The Controls Engineer designs, programs, and commissions industrial automation control systems from concept through start-up. This role combines detailed electrical and controls design work with on-site integration, commissioning, and support at manufacturing facilities, with a strong focus on automotive applications and systems integration.

• Perform the complete design of automation control systems, including electrical and controls architecture for industrial applications.
• Review project specifications, internal standards, and industry standard practices to ensure compliance and alignment with customer requirements.
• Develop non-standard control system designs when required by project scope or customer needs.
• Follow internal and customer standards for hardware, software, and documentation throughout the design and implementation process.
• Create system map layouts and define the sequence of operations for automated equipment and processes.
• Develop complete drawing packages, including control panel layouts, wiring diagrams, and field device schematics.
• Program PLC logic and design HMI screens to meet functional and operational requirements.
• Specify control panel and field materials by creating detailed electrical bills of materials.
• Assist with installation oversight at customer facilities to ensure proper implementation of designed systems.
• Support system startup and debugging at customer sites, resolving issues and optimizing performance.
• Provide launch and standby support during production ramp-up to ensure reliable operation of control systems.
• Perform system integration activities, including start-up, commissioning, and rework of automation systems.
• Review cycle time studies and dimension switch layouts to validate system performance and ensure design meets production goals.
• Design logic for control systems and smart displays, ensuring clear operator interfaces and reliable functionality.
• Apply knowledge of system architecture, including non-standard materials, control panel power requirements, and power distribution.
• Review and interpret specifications, internal hardwired and logic standards, general specifications, and scope of work documents.
• Assist with installation and debugging activities independently, without requiring additional technical support.
• Collaborate with project teams while also working autonomously to meet project deadlines and quality standards.
• Travel to customer manufacturing facilities for on-site design validation, integration, commissioning, and support.
• Perform physical tasks on job sites, including climbing ladders, walking job sites, and carrying a laptop while inspecting equipment and systems.

• Relevant bachelor's or associate degree in engineering or technology, or equivalent relevant work experience with a technical degree.
• 5+ years of industry experience working for a systems integrator, including control panel and circuit design.
• Hands-on experience with non-standard designs, system map layouts, and sequence of operations for automated systems.
• Experience reviewing cycle time studies and designing dimension switch layouts to meet production requirements.
• Ability to create complete design packages, including design logic, entry logic, and smart display designs.
• Strong knowledge of system architecture, including non-standard material selection, control panel power requirements, and power distribution.
• Ability to review and apply specifications and standard practices, including internal hardwired and logic standards, general specifications, and scope of work.
• Proficiency with RSLogix 5 and RSLogix 5000 for PLC programming.
• Proficiency with RSNetWorx for network configuration and diagnostics.
• Experience with Drive Executive and related drive configuration tools.
• Ability to assist with installation and debugging independently, without additional technical support.
• Ability to work both independently and in a team-oriented environment.
• Willingness and ability to travel to customer sites as needed.
• Ability to climb a two-story ladder safely.
• Ability to walk a mile in approximately 20 minutes and cover a reasonable distance on foot at job sites.
• Ability to lift up to 30 pounds without difficulty, including while carrying a laptop computer.

• Experience in automotive manufacturing environments and systems integration.
• Familiarity with Ford Next Gen standards.
• Familiarity with GM G12 standards.
• Proficiency with Microsoft Office Suite for documentation, reporting, and communication.
• Experience with start-up, commissioning, and rework of complex automation systems.
• Strong problem-solving skills and the ability to troubleshoot electrical and controls issues under time constraints.
• Effective communication skills for working with cross-functional teams and customer personnel.
• Comfort working autonomously in the field while maintaining alignment with project objectives and standards.

The role combines office-based design work with…