Controls Engineer

Job Title:
Automation Lead Engineer

The Automation Lead Engineer will drive automation initiatives at an onsite battery manufacturing plant in St. Joseph, MO. This role is ideal for an engineer with deep expertise in PLC programming, controls integration, and industrial networking, combined with a strong understanding of mechanical systems and automation hardware. The engineer will collaborate closely with internal teams and external vendors to identify automation opportunities, optimize manufacturing processes, and lead the specification, design, and integration of new automation systems into existing production lines.

• Lead automation projects with a primary focus on PLC programming, controls architecture, and system integration for manufacturing lines.
• Collaborate with Manufacturing Engineering, Controls Engineering, and Operations teams to identify process inefficiencies and develop automation solutions.
• Work directly with suppliers and vendors to specify, design, build, and integrate new automation equipment into existing manufacturing lines.
• Conduct facility inspections and gather real-time production and equipment data to inform engineering and design decisions.
• Support procurement activities, commissioning, and troubleshooting of automation systems, controls hardware, and related equipment.
• Ensure automation systems support compliance with safety standards, environmental regulations, and plant protocols.
• Document control logic, system architecture, operating procedures, and training materials for internal engineering and operations teams.
• Stay current with emerging technologies in industrial automation, robotics, smart manufacturing, and industrial IoT, and recommend improvements based on these developments.
• Configure and optimize vision systems, including camera setup, calibration, and integration with control systems.
• Modify and create PLC logic to improve system performance, reliability, and throughput, with a focus on strong troubleshooting and optimization.
• Perform basic HMI configuration tasks, including navigating HMIs, creating pop-up boxes, and implementing error and warning messages.
• Interface with Fanuc robots to position robots, create interlocks with the main line, and troubleshoot issues that occur during operation.

• Minimum of 7+ years of experience in controls engineering within a manufacturing environment.
• Proficiency in PLC programming, with Allen-Bradley/Rockwell platforms preferred, using Studio 5000 (multiple versions) and primarily Ladder Logic with some Structured Text.
• Ability to modify and create PLC logic and apply strong troubleshooting skills aimed at system optimization.
• Experience in controls architecture and system integration for automated manufacturing processes.
• Proficiency in HMI development and configuration, including basic navigation, pop-up creation, and error/warning messaging using tools such as Factory Talk View and Ignition.
• Strong understanding of industrial networking concepts and implementation in automation environments.
• Experience working with external vendors to develop and integrate custom automation solutions and capital equipment.
• Solid understanding of automation hardware, including sensors, actuators, drives, vision systems, and control panel design.
• Hands‑on experience with industrial vision systems such as Keyence and Cognex, including camera setup and configuration.
• Foundational knowledge of robotics, specifically Fanuc robots, including positioning, creating interlocks with main production lines, and troubleshooting operational issues.
• Bachelor’s degree in Mechanical, Electrical, Mechatronics, Controls, or Manufacturing Engineering, or equivalent relevant experience.

• Experience in battery manufacturing, automotive, or other high-volume production environments.
• Knowledge of SCADA and MES systems, data acquisition, and industrial IoT technologies.
• Exposure to sustainability practices and energy-efficient automation design.
• Experience with capital equipment projects, including specification, installation, and optimization.
• Strong problem-solving skills with the ability to…