Controls Engineer

Job Title:

Controls Engineer

Job Description

The Controls Engineer develops, programs, and supports industrial control systems in a fast-paced manufacturing environment, with a strong focus on shop-floor troubleshooting and launch support for new and updated machining and assembly processes. This role uses Factory Information Systems (FIS) data and plant monitoring tools to improve equipment performance, integrates controls with plant IT systems, and works hands-on with PLCs, robots, and automation to ensure reliable, safe, and efficient production operations.

Responsibilities

+ Develop and implement improvements to control systems and equipment using Factory Information Systems (FIS) data and plant monitoring tools.

+ Lead problem-solving activities to resolve equipment performance issues, including identifying root causes and implementing robust corrective actions.

+ Lead troubleshooting efforts for machinery, robots, automation, and controls-related issues and downtime on the shop floor.

+ Coordinate resources across maintenance, vendors, and process teams to break complex problems into actionable, verifiable tasks.

+ Use FIS plant monitoring software to review and analyze equipment cycle times and identify opportunities for optimization.

+ Assist in integrating controls systems into IT platforms such as Factory Information Systems (FIS), Error Proofing systems, QWX, and QTS.

+ Review and coordinate project installations for new or modified equipment and automation systems.

+ Reprogram equipment to support engineering changes, process improvements, and product updates.

+ Maintain and manage program backups for machinery, automation systems, and robots to ensure quick recovery and configuration control.

+ Program new installations of automation equipment, machinery, material handling systems, and industrial robots.

+ Review and participate in equipment safety risk assessments as part of a cross-functional team to ensure compliance with safety standards.

+ Assist in training manufacturing personnel and plant electricians on controls, automation systems, and troubleshooting methods.

+ Support PLC-controlled manufacturing equipment, production interlocks, safety systems, and automated stations during pre-production, launch, and early production ramp-up phases.

+ Validate control system changes directly on the shop floor with operations, maintenance, and process teams.

+ Support multiple work streams in parallel, driven by production readiness timelines, launch milestones, and change implementation requirements.

Essential Skills

+ 5+ years of related controls engineering or controls-focused experience, ideally in a manufacturing environment, with or without a completed engineering degree.

+ Hands-on experience supporting manufacturing equipment on the shop floor and troubleshooting controls-related issues.

+ Strong PLC programming experience, with Siemens PLC programming as a must-have skill.

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Experience with PLC controllers such as Siemens, Rexroth, and Allen-Bradley.

+ Proficiency with Siemens Step 7 and TIA Portal programming and troubleshooting.

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Experience with Siemens power line and solution line configuration and programming.

+ Ability to troubleshoot Fanuc controls and industrial robots.

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Experience with CNC machines and automated manufacturing equipment.

+ Familiarity with industrial robots and/or vision systems, with experience considered a strong plus.

+ Ability to work effectively with union maintenance teams, external vendors, and internal process team members.

+ Strong oral and written communication skills for effective collaboration and documentation.

+ Proficiency with Microsoft Office applications, including Excel, PowerPoint, and Outlook.

+ Demonstrated problem-solving skills using methods such as 8D and 5 Why analysis.

+ Knowledge and application of Lean Manufacturing and Six Sigma principles.

+ Experience using Lean tools such as 5S, Kanban, Poka-yoke, and Value Stream Mapping.

+ Familiarity with UL508A requirements and NFPA 79 for industrial control panels and electrical safety.

Additional

Skills & Qualifications

+ High school diploma required, with 5+ years of related controls or manufacturing engineering experience.

+ Bachelor's degree in Engineering preferred.

+ Experience working in fast-paced, launch-driven manufacturing environments.

+ Comfort working primarily on the shop floor rather than in a desk-based or remote setting.

+ Ability to manage multiple priorities and work streams in parallel as launch milestones approach.

+ Strong teamwork and collaboration skills with cross-functional operations, maintenance, and engineering teams.

+ Gear-specific experience is not required, making this role suitable for candidates from diverse manufacturing backgrounds.

Work Environment

This is a first-shift, on-site position with standard hours of 6:00 a.m. to 2:30 p.m., Monday through Friday. Minimal overtime may be required and, when needed, is typically worked at the end of the shift. Occasional Saturday work may be required,…