Controller Engineer

Job Description

AESC is looking to add a Controller Engineer to our team in Smyrna, TN.

• Full-Time
• On-site

AESC is an exciting, newly created global organization committed to solving the challenges of a sustainable future and becoming the leading supplier of full-value-chain battery solutions. Our lithium-ion batteries can be found in nearly one million electric vehicles worldwide and have a stellar safety record of zero-critical issues. AESC US is leading the way in battery technology. We design and manufacture EV battery technology for various electric vehicles and equipment.

We are working hard towards unlocking the full potential of sustainable energy and climate change mitigation. We will continue to build upon our successes and expand into new markets and industries, producing innovative and competitive products and technologies that advance the goal of a zero-carbon emission future. AESC is headquartered in Japan and has battery manufacturing locations in Japan, UK, China, and the U.S.

Our mission is to solve the challenges for a sustainable future. Together, we can make a meaningful impact.

• Manufacturing Process Implementation:
  Lead the implementation and launch of all manufacturing processes to production readiness and support post-SOP (Start of Production).
• Equipment Installation and Commissioning:
  Install, commission, and qualify new equipment and tooling in collaboration with vendors and internal teams to ensure seamless production integration.
• Continuous Improvement:
  Utilize root cause analysis, Design of Experiments (DOE), and other methodologies to achieve and enhance process capabilities.
• Documentation and Training:
  Develop and maintain process documents such as Work Instructions (WI) and conduct training for production employees, including technicians, team leaders, and maintenance personnel.
• Failure Mode and Effects Analysis (FMEA):
  Own the FMEA process for your assigned area, documenting lessons learned and driving continuous improvement initiatives.
• Controls Engineering Integration:
  Ensure robust integration between equipment controls and site MES/SCADA systems, collaborating with facility design teams for optimized control system compatibility.
• Control Systems Development:
  Design and develop PLC/HMI control systems, motion control, robotics, and sensors to automate manufacturing processes, including material handling, assembly, testing, and packaging.
• Control Systems and Protocols:
  Familiarity with protocols such as Profinet, Modbus
  
  TCP, Ethernet/IP, BACnet, OPC. Proficiency in programming languages used in PLC-controlled facilities:
  Structured Text, Ladder Logic, Function Block Diagram, Sequential Function Chart (SFC), IEC 61131-3 Standard, JSON.
• Programming:
  Responsible for the design, implementation, and lifecycle ownership of structured, maintainable control software for high-volume battery manufacturing equipment. This role sets and enforces structured programming standards, with a strong emphasis on IEC 61131-3 Structured Text (ST) to ensure safe, scalable, and supportable automation systems.
• SCADA/HMI Development:
  Work with the team to develop standard HMI and SCADA designs using Ignition by Inductive Automation.
• Instrumentation:
  Assist process engineers with selecting and placing instrumentation, including air particle sensors, flow, pressure, and temperature sensors.
• Automation and Standardization:
  Select and integrate automation components such as PLCs, HMIs, drives, sensors, and robotics. Standardize and optimize control system architectures and logic.
• Troubleshooting and Optimization:
  Lead troubleshooting and continuous improvement initiatives to enhance equipment effectiveness and process automation.
• Leadership:
  Exhibit strong leadership qualities by guiding team members, fostering a collaborative and innovative work culture, and solving challenges with a forward-thinking mindset.
• Complete other duties as assigned.

• Education:
  
  Bachelor’s degree in electrical, Controls, Mechatronics Engineering, or a related field.
• Experience:
  
  Minimum of 5 years of experience in controls engineering or process/manufacturing engineering, ideally within the automotive or battery manufacturing sectors.
• Technical Expertise:
  Proficiency in PLC/HMI programming (e.g., Siemens, Rockwell Automation), control systems integration, and automation component selection.
• Software
  
  Skills:
  
  Proficiency in Microsoft Office Suite (Word, Excel, PowerPoint), CAD, Minitab, and data analysis tools. Advanced skills in control system development environments such as Siemens Step 7, Studio 5000, or equivalent.
• Problem-Solving
  
  Skills:
  
  Strong analytical and troubleshooting abilities, with experience in root cause analysis, DOE, FMEA, and 8D methodologies.
• Communication and Leadership:
  Excellent interpersonal and communication skills, with the ability to lead cross-functional teams and collaborate effectively across departments and cultural boundaries.
• Global…