Automation Architect: PLC-to-MES; Ground

Location: Warren, Michigan
Industry: Automotive Manufacturing
Role Type: Controls / Automation / MES Engineering

We are seeking an experienced Controls / MES Engineer to support a ground-up manufacturing automation implementation for a major automotive manufacturer in Warren, Michigan.

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.

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 Engineering, or a related discipline.

The strongest…