Controls Design Lead - Automation Systems

Job Description

Job Description

Location: Detroit Metropolitan Area
(Hybrid: 3 days Work From Home, 2 days In Office)

AlfaITG is a leading tooling company providing cradle-to-grave engineered solutions for the manufacturing industry, incorporating Artificial Intelligence to enhance and differentiate both AlfaITG and our customers. We are a nimble, fast-growing systems integrator that designs, builds, and installs automation systems for leading North American and global OEMs.

We specialize in taking a customer's product concept from a clean sheet of paper and engineering and building a complete system to produce that product efficiently, within specified cycle times, and to the highest quality standards. Our multidisciplinary team marries mechanical design, controls, and manufacturing know-how to deliver turnkey automation cells-on time, on budget, and production ready.

In this role, you will own the controls design function across projects and play a key role in shaping how AlfaITG delivers robust, scalable automation systems.

The Controls Design Lead is responsible for leading the design, development, and implementation of electrical and controls systems for custom automation equipment. This includes full ownership of controls architecture, hardware selection, PLC/HMI development, and system integration across tools and complete production cells.

This role combines technical leadership with hands‑on execution, including involvement in quoting, early concept development, and supporting system commissioning.

• Lead controls design activities across automation projects from concept through launch
• Define and standardize controls architecture for:
  • Standalone tooling (geo-fixtures, EOAT, pass tables, etc.)
  • Integrated automation systems and full production cells
• Design and configure electrical systems including:
  • PLC hardware and network architecture
  • I/O systems and field device integration
  • Power distribution and panel layouts
• Develop electrical schematics and documentation (EPLAN, AutoCAD Electrical, or similar)
• Specify and select controls hardware (PLCs, HMIs, drives, safety systems, sensors, etc.)
• Lead PLC and HMI programming efforts, including:
  • Developing preliminary and production‑ready PLC code
  • Establishing program structure and standards
  • Supporting debug and commissioning
• Integrate and support robotic systems (e.g., FANUC, ABB, KUKA) in coordination with robot programmers
• Participate in system bring‑up, debug, and launch both in‑house and on customer sites
• Support quoting and proposal development for new automation opportunities
  • Define controls scope, architecture, and level of effort
  • Estimate engineering hours for controls design, programming, and commissioning
  • Develop preliminary bill of materials (BOMs) for controls hardware
  • Provide input on technical risk, complexity, and cost drivers

• Degree in Electrical Engineering, Mechatronics, or related field (or equivalent experience)
• 8-12+ years of experience in controls design within automation or systems integration
• Proven experience leading controls design for automotive manufacturing systems
• Strong experience with PLC platforms (one or more):
  • Rockwell / Allen‑Bradley
  • Siemens, Omron, or others
• Experience with HMI/SCADA systems (Factory Talk, WinCC, etc.)
• Strong knowledge of:
  • Electrical design and panel layout
  • I/O systems and industrial networking (Ether Net/IP, Profinet, etc.)
  • Safety circuits and standards (e.g., safety PLCs, relays)
• Experience supporting robotic integration (FANUC, ABB, KUKA, etc.)
• Ability to develop structured, scalable PLC programs

• Experience in automotive body‑in‑white (BIW) or light assembly environments
• Familiarity with OEM standards (Ford, GM, Stellantis)
• Experience with simulation,…