Controls Engineer

Overview

Role Summary

The Controls Engineer is responsible for integrating automation controls for new products being launched into production, as well as implementing improvement activities for products currently in production. This role is responsible for maintaining and troubleshooting automation controls in support of operations. This position is also responsible for integrating new technologies into existing equipment. The Controls Engineer participates in 8D resolution, scrap reduction, downtime reduction, and cost reduction activities.

• Assist the Maintenance department with troubleshooting machines through PLC ladder logic, STL, and SCL
• Write new PLC logic and perform hardware/software upgrades as necessary to support Kaizen or corrective action requests
• Integrate third-party equipment including torque guns, crimp devices, leak test units, barcode scanners, and servomotors
• Support the effective launch of new products and seamless transition of current products from Advanced Engineering to Operations (Engineering Changes)
• Perform time studies, line balancing, and implement improvements to current production processes
• Actively engage line-side production boards (RPS) to identify opportunities for improvement
• Maintain, update, and audit Visual Work Instructions and Standard Work for operators in assigned production cells
• Develop statements of work/specifications for changes to existing machines and fixtures
• Attend new design proposal reviews and provide recommendations regarding manufacturability and compatibility with current manufacturing operations
• Attend layout reviews for new products and provide recommendations for process flow, product assembly, and equipment
• Perform internal process development of new and existing tooling
• Review the performance of process changes or machine improvements with the Quality department to ensure compliance with customer requirements
• Revise process FMEA, control plan, and production flow for design changes
• Assist Production Engineering with customer run-at-rates for new programs
• Maintain required skills through training and studying engineering and technical publications to remain current on technological changes and industry developments
• Investigate and implement countermeasures for internal and external quality or safety concerns

Education and Experience

• Bachelor’s degree in Engineering (or related discipline) with at least three (3) years of experience in manufacturing automation programming and troubleshooting, OR
• A.A.S. degree with five (5) years of experience as a Manufacturing Engineer working with manufacturing automation programming and troubleshooting

• Knowledge of mechanics of machines and motion, heat transfer, fluid dynamics, and strengths/mechanics of materials
• Knowledge of torque guns, crimp devices, leak testing, and servos

• Rockwell control logics
• RSLogix 500
• Factory Talk
• Siemens Step 7
• WinCC Flex
• TIA Portal PLC/HMI software