Controls Engineer

Summary:

Controls Engineer will serve as an automation and assembly specialist in the design, construction, and implementation of assembly equipment control systems and standards. Leads activities concerned with the development and implementation of assembly equipment control systems and standards to fulfill the production requirements for new and current programs.

Essential Duties and Responsibilities:

Design electrical schematics, encompassing controls, safety, power circuits, pneumatic systems, bill of materials, and panel layouts for custom automation systems, meeting both internal and customer specifications. Collaborate with Mechanical Engineers to integrate electrical, pneumatic, and mechanical designs.

Conduct equipment diagnostics and design using PLC and HMI, applying a broad knowledge of technical principles to ensure safety, performance, and reliability.

Provide expertise and guidance in the identification, analysis and resolution of problems.

Assist in the creation and review of FMEAs and Control Plans.

Continuously analyze products and processes to identify opportunities for cost reduction and efficiency improvement.

Test, troubleshoot, and debug automation systems, adhering to internal test scripts and customer-provided factory acceptance test protocols.

Create and edit operation and troubleshooting manuals for automation systems.

Provide support to the Engineering team by contributing to costing, electrical and controls concepts for new applications.

Ensure adherence to project budgets, schedules, and deadlines.

Coordinate and conduct validations, including Installation Qualification (IQ), Operational Qualification (OQ), and Performance Qualification (PQ).

Investigate and implement new methods, layouts, equipment, and process analyses to enhance overall plant operations.

Develop and implement work instructions and standardization of processes.

Troubleshoot processes that are prone to frequent or major production problems.

Offer technical support to various departments, including manufacturing, engineering, quality, marketing, customer service, and management as needed.

Participate in "special projects" as required.

Comply with OSHA safety and health regulations, as well as other federal, state, and local regulations related to environmental, industrial and electrical mandates.

Leadership Expectations:

Strategically Positions the Business:

Understand customer-specific requirements and define the personnel and technical resources necessary to deliver on-time, high-quality service and meet customer expectations, thereby accelerating revenue growth and increasing customer satisfaction.

Delivers Results:

Be accountable for forecasting and delivering monthly financial performance metrics related to revenue, labor, and costs, aligning with annual plan objectives.

Leads Effectively:

Lead and facilitate customer-facing communication, proactively resolving issues through close collaboration with sales, engineering, manufacturing, quality, outside vendors, and other key stakeholders.

Talent Development:

Champion the Leadership Development framework by sourcing, developing, and retaining a diverse talent pipeline, identifying key leaders for future roles.

Qualifications:

Bachelor's Degree in Engineering (Manufacturing, Electrical, or Mechanical) preferred.

A minimum of 4+ years of related work experience in a Manufacturing Engineering role in a high-volume manufacturing environment is required.

Proficiency in Allen-Bradley PLC systems is a mandatory requirement.

Experience with ignition and other “middleware” preferred.

Experience with LabView preferred.

Experience with SQL data management preferred.

Strong ability to read and comprehend complex instructions, safety rules, operating and maintenance instructions, and procedure manuals.

Strong working knowledge of Process Flow, Control Plan, PFMEA, Statistical Process, and Machine Controls.

Demonstrated understanding of engineering theories and principles

Strong Knowledge of ISO 14001/TS 16949.

Ability to execute detailed, complex oral or written instructions.

Proficiency in applying problem-solving techniques to address complex issues.

Excellent communication and listening skills.

Microsoft Office, AutoCAD or other drafting software.

Electrical and mechanical knowledge.