Controls Engineer

Job Overview

As a Controls Engineer reporting to the Head of Supervisors, you will provide advanced controls engineering expertise to diagnose, troubleshoot, and resolve a wide range of manufacturing process issues. The role supports production operations by improving key plant performance metrics, including equipment downtime, customer PPM, defect rates, and overall process reliability.

This position supports all aspects of Controls Engineering, including PLC/HMI systems, automation reliability, industrial networks, traceability systems, and manufacturing data management. It partners with cross‑functional teams to drive continuous improvement initiatives, support root cause analysis, and ensure stable, efficient, and repeatable automated processes.

• Lead and support equipment troubleshooting events in collaboration with process engineering and maintenance.
• Participate with project teams to define and develop PLC programs for the plant, targeting improvements in safety, quality, and productivity metrics.
• Perform automation start‑up and post start‑up support for internal and external customer projects, both on the software and hardware side.
• Provide internal and external customer project feedback for continuous improvement.
• Support the First‑time Thru Quality initiative while customizing PLC programs.
• Document and maintain records of projects and PLC revisions.
• Design, program, and troubleshoot PLCs (Allen Bradley, Siemens, Omron) and HMIs (Panel View, WinCC, Weintek).
• Develop and integrate control systems for automation equipment, robotics (KUKA, FANUC, Kawasaki), and vision systems (Keyence, Cognex).
• Lead system integration projects, including testing, debugging, commissioning, and documentation.
• Supervise installation and adjustment of control systems to meet specifications and compliance standards.
• Manage project scope, schedule, and budget, ensuring timely delivery and cost control.
• Coordinate cross‑functional teams (maintenance, production, engineering, vendors) to support automation upgrades and new line launches.
• Provide technical leadership and mentorship to junior engineers and technicians.
• Ensure compliance with NEC, NFPA, OSHA, and industry safety standards.
• Support continuous improvement initiatives using Lean Manufacturing, Six Sigma, and Just‑In‑Sequence concepts.
• Upgrade and maintain production computer systems, including Device Wise, SQL, ACC, and LabVIEW.

• Bachelor’s degree in Mechanical, Electrical, or Mechatronics Engineering with extensive experience in automated process environments.
• Minimum of 3 years of experience in programming with Allen Bradley Rockwell Automation Software, including Studio 5000, and Siemens S7.
• Proficiency in Control Logix/RSLogix 5000, SLC 500/RSLogix 500, and ability to program using Ladder Diagram, Functional Block Diagram, Structured Text, and HMI Panel View.

MAHLE is not currently hiring individuals for this position who now or in the future require sponsorship for employment‑based non‑immigrant and immigrant visas. However, as a global company, MAHLE offers many job opportunities outside of the USA which can be found through our employment website.

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