Controls Engineer

Position SummaryThe Controls Engineer is responsible for the design, development, implementation, and continuous improvement of automation and control systems within a high-volume automotive interior manufacturing environment. This role plays a critical part in ensuring equipment reliability, production efficiency, safety compliance, and overall manufacturing excellence through advanced programming, troubleshooting, and system optimization.Key ResponsibilitiesAutomation & Controls EngineeringDesign, program, and troubleshoot PLC and HMI systems, primarily using Allen-Bradley platforms (SLC 500, MicroLogix, CompactLogix, PanelView).Develop and support industrial communication networks (Ethernet/IP, DH+, DH-485, RS-232).Integrate and support advanced manufacturing technologies including robotics, vision systems, servo systems, and MES connectivity.Maintain and update electrical schematics using AutoCAD.Equipment & Production SupportProvide hands-on technical support to production and maintenance teams to minimize downtime and improve equipment performance.Diagnose and resolve electrical and controls-related issues, including AC/DC circuits, sensors (PNP/NPN), and industrial networks.Support new equipment installation, commissioning, and machine buyoffs to ensure compliance with plant standards and specifications.Continuous ImprovementLead and participate in continuous improvement initiatives focused on: Cycle time reductionEquipment uptime and reliabilityQuality enhancement and error-proofing (Poka-Yoke)Identify and implement new technologies to improve manufacturing efficiency and product quality.Project & Launch SupportParticipate in equipment quoting, design reviews, and vendor selection to ensure cost-effective and standardized solutions.Support new product and equipment launches, ensuring adherence to safety standards and operational readiness.Manage multiple projects and priorities in a fast-paced manufacturing environment.Training & DocumentationTrain maintenance and operations personnel on new equipment, technologies, and troubleshooting techniques.Maintain and update plant-wide controls standards and documentation.Establish and manage electrical spare parts inventory (crib stock).Experience with AC Power from 480VAC 3ᴓ to 110Vac, and 24 VDC Control circuitsEducation & ExperienceAutomotive interior or Tier 1 supplier experience preferred. Bachelor’s degree in electrical engineering or related field preferred.Minimum of 5 years of controls engineering experience in a manufacturing environment Experience with fully automated assembly systems featuring integrated Poka-Yoke and MES. Demonstrated success implementing new automation technologies into existing production lines.Experience with automated assembly systems; injection molding experience is a strong plus.Technical ExpertiseStrong knowledge of PLC programming and HMI development Working knowledge of pneumatics and hydraulics.Experience with:Robotics (Fanuc, ABB preferredVision systems (Keyence, Cognex)MES integrationDC torque tool interfacesProficiency in electrical troubleshooting across:480VAC 3-phase systems110VAC systems24VDC control circuitsAdditional SkillsAbility to manage multiple projects and priorities effectively.Experience with machine buyoff procedures and equipment validation.Strong communication and collaboration skills across all organizational levels.Proficiency with Microsoft Office applications.