Controls Engineer

This role leads complex engineering projects involving PLC programming, HMI development, industrial automation, electrical system design, test equipment integration, and continuous improvement initiatives. This role works closely with Manufacturing, Quality, Maintenance, Product Engineering, and Operations teams to improve safety, quality, delivery, and cost performance while supporting future growth and automation strategies.

Essential Duties and Responsibilities Controls & Automation Engineering

• Design, program, troubleshoot, and optimize PLC-based control systems for manufacturing and test equipment.
• Develop and support HMI, SCADA, and industrial automation systems.
• Design electrical control panels, schematics, wiring diagrams, and power distribution systems.
• Lead automation projects focused on improving productivity, quality, safety, and equipment reliability.
• Evaluate and implement new automation technologies and manufacturing control systems.

Manufacturing Equipment & Test Systems

• Develop specifications for manufacturing equipment, automated assembly systems, fixtures, and electrical test stations.
• Support installation, commissioning, validation, and startup of new equipment.
• Troubleshoot complex electrical, controls, and automation-related production issues.
• Develop and maintain engineering test standards and validation procedures.
• Improve Overall Equipment Effectiveness (OEE) through controls and automation enhancements.

Product & Process Support

• Support new product development activities through Design for Manufacturability (DFM) and Design for Testability (DFT) reviews.
• Partner with Product Engineering to ensure manufacturing requirements are incorporated into product designs.
• Support prototype builds, pilot production runs, and production launch activities.
• Recommend manufacturing methods, process changes, and equipment improvements based on engineering analysis and cost studies.
• Lead root cause investigations involving electrical systems, controls, test equipment, and automation failures.
• Utilize structured problem-solving methodologies including 8D, DMAIC, Fishbone Analysis, and 5 Why.
• Develop and implement corrective actions to eliminate recurring issues and improve system performance.
• Drive continuous improvement initiatives related to safety, quality, delivery, and cost.

Cross-Functional Leadership

• Serve as the primary controls and automation subject matter expert for the facility.
• Partner with Operations, Quality, Maintenance, Product Engineering, and Supply Chain teams to support business objectives.
• Provide technical leadership, coaching, and mentoring to engineers, technicians, and maintenance personnel.
• Present project status, technical findings, and recommendations to leadership teams.

Project Management

• Lead capital equipment and automation projects from concept through implementation.
• Develop project scopes, schedules, budgets, and resource requirements.
• Monitor project performance and recommend changes in design, procedures, or objectives as necessary.
• Ensure projects are completed on time, within budget, and in compliance with company standards.

Additional Responsibilities

• Support compliance with applicable electrical, safety, and regulatory standards.
• Participate in risk assessments and equipment safety reviews.
• Perform other duties and special projects as assigned.

Required Qualifications Education

• Bachelor's Degree in Electrical Engineering, Controls Engineering, Automation Engineering.

Experience

• Minimum seven (5) years of professional engineering experience in manufacturing, controls, automation, or electrical systems engineering.
• Experience designing and troubleshooting industrial control systems.
• Experience supporting high-volume manufacturing operations.

Preferred Qualifications

• Experience with battery manufacturing, electrification products, or automated assembly operations.
• Experience programming Allen-Bradley, Siemens, or similar PLC platforms.
• Experience with HMI and SCADA systems.
• Experience with industrial robotics and machine vision systems.
• Experience with automated test equipment and data acquisition systems.
• Lean Six Sigma Green Belt or Black Belt certification

preferred.

Knowledge, Skills & Abilities

• Advanced knowledge of PLC programming, industrial controls, and automation systems.
• test systems, vision, PLC, laser, cycle time reductions, constraint elimination, MTBF increases, MTTR reductions
• Advanced understanding of electrical power distribution, motor controls, sensors, and industrial networks.
• Strong troubleshooting…