Controller Engineer

Overview

AESC is looking to add a Controller Engineer to our team in Smyrna, TN. This is a full‑time, on‑site position.

• Manufacturing Process Implementation:
  Lead the implementation and launch of all manufacturing processes to production readiness and support post‑SOP.
• 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 and conduct training for production employees, including technicians, team leaders, and maintenance personnel.
• Failure Mode and Effects Analysis (FMEA):
  Own the FMEA process for the 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, ModbusTCP, 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 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 in controls engineering or process/manufacturing engineering, ideally within automotive or battery manufacturing sectors.
• Technical Expertise:
  Proficiency in PLC/HMI programming (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, 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 Perspective:
  Willingness and ability to travel up to 25%, including overseas travel to vendor and sister locations in China, South Korea, or Japan during the industrialization phase. Understands and follows IATF
  16949 and VDA 6.3 quality standards. Training and awareness will be provided…