Controls Engineer

We are seeking an experienced Controls Engineer to support a ground-up manufacturing automation implementation for a major automotive manufacturer in Maumee, Ohio.

This is primarily a new-build development and implementation role, not a sustaining or maintenance position. The engineer will be responsible for designing, programming, integrating, and commissioning controls and manufacturing systems, with a strong focus on Rockwell Studio 5000, Ignition, and PLC-to-MES integration.

The ideal candidate has personally taken automation systems from initial design through commissioning and production launch and can demonstrate hands‑on experience developing PLC, HMI/SCADA, and MES functionality rather than only modifying or troubleshooting existing systems.

• Design and develop Allen‑Bradley Control Logix/Guard Logix PLC programs from the ground up using RSLogix 5000 / Studio 5000.
• Develop PLC architecture including ladder logic, tag structures, UDTs, AOIs, sequencing, diagnostics, alarms, and equipment interfaces.
• Design and build Ignition HMI/SCADA applications, including screens, tags, scripting, alarms, communications, and system configuration.
• Develop and implement communication between PLCs and MES systems.
• Create PLC/MES transaction and handshake logic for manufacturing operations.
• Support work‑order verification, part and serial‑number traceability, recipe/model management, production reporting, and pass/fail transactions.
• Integrate barcode scanners, RFID systems, and other production tracking equipment.
• Configure and integrate Zebra industrial label printers, including generation and implementation of ZPL code.
• Develop automated label‑printing processes tied to production events, work orders, and cycle completion.
• Perform controls system startup, debugging, commissioning, FAT/SAT, and production launch activities.
• Troubleshoot PLC, HMI, MES, networking, and equipment communication issues as needed.
• Collaborate with manufacturing engineering, IT/MES teams, equipment integrators, and plant personnel throughout implementation.
• Develop and maintain controls documentation, system architecture, backups, and commissioning records.

• Strong hands‑on experience with Allen‑Bradley Control Logix/Guard Logix and Studio 5000 / RSLogix 5000.
• Demonstrated experience writing new PLC programs for equipment, stations, or production lines from scratch.
• Hands‑on experience with Inductive Automation Ignition.
• Experience developing Ignition screens, tags, scripting, and/or application architecture.
• Experience integrating PLCs with MES or manufacturing information systems.
• Understanding of manufacturing transactions such as work‑order validation, traceability, recipes, production reporting, and serial‑number tracking.
• Experience commissioning automated manufacturing equipment.
• Strong troubleshooting skills across controls hardware, PLC software, industrial networks, and production systems.
• Experience in automotive or other high‑volume discrete manufacturing environments.

• Experience generating ZPL code and integrating Zebra industrial printers.
• Experience with barcode and RFID‑based production traceability.
• Ignition Vision and/or Perspective development experience.
• Industrial networking experience including Ethernet/IP, OPC UA, SQL, or related communication technologies.
• Experience taking a controls project through the complete lifecycle: design → development → integration → startup → commissioning → production launch.
• Bachelor's degree in Electrical Engineering, Controls Engineering, Mechatronics, Automation, Industrial…