Senior Controls Engineer

We are seeking a Controls Engineer to support Body production operations by maintaining, troubleshooting, and improving automation and control systems. This role is responsible for ensuring maximum uptime, implementing running changes, and continuously improving PLCs, HMIs, robots, vision systems, and automation equipment to deliver safe, efficient, and high-quality production.

• Provide hands‑on troubleshooting and support for PLCs, robots, motion controls, and vision systems in BIW production.
• Diagnoses and resolve automation‑related downtime quickly to minimize production impact.
• Modify and optimize PLC logic, HMI screens, and robot programs to improve operator and maintenance usability.
• Support running changes, equipment upgrades, and control system updates with minimal disruption to production.
• Conduct root cause analysis for automation‑related failures, throughput issues, and quality concerns; drive corrective actions.
• Partner with maintenance and engineering teams to develop and maintain documentation, training, and preventive maintenance plans.
• Ensure compliance with safety standards, perform risk assessments, and maintain safe control logic (safety PLC, interlocks, DCS).
• Track system performance, identify recurring issues, and implement continuous improvement initiatives in safety, quality, and uptime.
• Collaborate with production supervisors, quality, and dimensional engineering to support daily plant operations.

• Bachelor’s degree in Electrical, Mechanical, Mechatronics, Computer Science, or related field.
• 5–7 years of experience as a Controls/Automation Engineer in a high‑volume manufacturing environment (automotive BIW preferred).
• Proficiency with PLC programming and troubleshooting (Siemens, Rockwell, or equivalent).
• Experience with HMIs/SCADA systems (WinCC, TIA Portal, Ignition SCADA, or similar).
• Hands‑on experience with industrial robots (Fanuc strongly preferred), dispense systems, and vision/bead detection systems.
• Strong troubleshooting and root cause analysis skills under production timing constraints.
• Knowledge of fieldbus networks, safety PLCs, and motion control systems.
• Familiarity with IATF 16949, PFMEA, and control plan methodology.
• Ability to standardize and document controls processes for plant‑wide use.