Maintenance and Controls Engineer

We are currently developing the next generation of high-performance battery systems tailored for diverse sectors, including robotics, marine, military, commercial electric vehicles, material handling, and aerial work platforms. We are looking for a skilled Maintenance & Controls Engineer to join our team in Mason, Ohio, and help drive the continuous improvement of our advanced manufacturing processes. This role offers a unique opportunity to take a hands-on approach to our engineering operations. You will be instrumental in optimizing equipment uptime, managing automated production systems, and executing both preventive and predictive maintenance strategies. If you are passionate about resolving complex technical challenges, commissioning state-of-the-art equipment, and contributing to the growth of a leading U.S. manufacturing firm, we invite you to apply. Key Responsibilities Ensure manufacturing productivity remains high by maintaining and troubleshooting our automated production machinery. Identify and resolve failures across electrical, mechanical, pneumatic, hydraulic, servo, and controls systems to keep operations running smoothly. Manage the programming, troubleshooting, and modification of PLCs, HMIs, motion control systems, and other industrial automation hardware. Assist in the installation, startup, commissioning, and validation of new production lines and manufacturing equipment. Create and implement maintenance schedules to improve equipment reliability and help minimize unexpected downtime. Utilize structured problem-solving techniques like 5-Why, Fishbone, and Failure Mode Analysis to lead root cause investigations. Maintain comprehensive records, including electrical drawings, PLC backups, spare parts inventory, and equipment documentation. Support a wide range of technologies, including industrial and collaborative robots, assembly equipment, conveyors, vision systems, and end-of-line testing tools. Diagnose issues within industrial networking, Ethernet/IP, I/O systems, sensors, actuators, servo drives, and VFDs. Design, update, and enhance machine electrical systems and control panels to improve overall performance. Collaborate with Manufacturing Engineering to boost cycle times, quality, ergonomics, and total throughput for the team. Evaluate equipment performance metrics such as OEE, MTBF, MTTR, and downtime reports to drive operational efficiency. Propose and execute capital improvements and automation upgrades to support cost-reduction goals. Maintain essential facility infrastructure, including compressed air, HVAC interfaces, and electrical distribution systems. Promote a culture of safety by ensuring strict adherence to OSHA, NFPA 70E, Lockout/Tagout, and internal safety protocols. Work alongside Quality, Manufacturing, and Test Engineering teams to facilitate rapid resolution of production challenges. Manage work orders, preventive maintenance schedules, and spare parts tracking through the Odoo ERP and MES platforms. Required Qualifications Bachelor’s degree in Mechatronics, Electrical, Controls, Mechanical, or Manufacturing Engineering, or a related technical field. Five or more years of experience in a production environment supporting automated manufacturing systems. Proven expertise in troubleshooting equipment controlled by PLCs. Proficiency with PLC platforms such as Allen-Bradley, Siemens, Beckhoff, Omron, or Mitsubishi. Experience with HMI development and industrial communication standards like Ethernet/IP, Profinet, DeviceNet, Modbus, or EtherCAT. Hands-on experience with motion control, variable frequency drives, servo systems, and industrial networks. Working knowledge of industrial robotics, including brands like FANUC, ABB, Universal Robots, Yaskawa, or Epson. Experience maintaining automated assembly, leak testing, vision, dispensing, and inspection systems. Ability to interpret and adjust electrical schematics, wiring diagrams, control panel layouts, and ladder logic. Proficiency in electrical design software such as AutoCAD Electrical or EPLAN is highly preferred. Deep understanding of machine safety, instrumentation, sensors, and industrial electrical systems. Experience with condition monitoring, vibration analysis, thermal imaging, and lubrication management is a plus. Familiarity with Six Sigma, Lean Manufacturing, Total Productive Maintenance (TPM), and other continuous improvement frameworks. Background in highly automated environments such as automotive, battery manufacturing, aerospace, medical devices, or semiconductors. Strong analytical capabilities to manage multiple projects while maintaining responsiveness to urgent production needs. Excellent communication skills to foster effective collaboration across cross-functional engineering and operations teams. Why You Should Join Us Contribute to the success of one of the fastest-growing advanced battery manufacturers in the country. Gain hands-on experience with cutting-edge battery production and automation technologies. Take a leading role in the launch of new manufacturing processes and production lines. Work alongside a talented team of engineers across product development and advanced technology departments. Receive a competitive salary package. Benefit from a comprehensive health and wellness plan. Participate in our 401(k) retirement program with company matching. Enjoy generous paid time off and holiday benefits. Access ongoing technical training and professional development opportunities. Benefit from clear pathways for career advancement as our organization grows. Technical Proficiencies Electrical Schematics Troubleshooting Skills Machine Building and Assembly Pneumatics Experience Single and Three Phase Power 120/208/240/480 Voltage Systems Industrial Robot Programming Troubleshooting Industrial Automation Equipment PLC Programming Experience SCADA Experience Programming Machine Vision Systems Electrical and Electronic Systems Pneumatics Troubleshooting Industrial Electrical Experience Industrial Electrical Systems Electrical Schematic Reading Equipment Installation and Wiring VLC Troubleshooting Technologies and Equipment Variable Frequency Drives (VFD) CAD Software Programmable Logic Controller (PLC) (Allen Bradley) Vision System Servo Motors Industrial Robot (Fanuc)