The Manufacturing Engineer – Controls supports automotive production by developing,
integrating, and maintaining automation, control systems, and manufacturing processes.
This role blends hands-on PLC/HMI programming with manufacturing engineering
responsibilities, ensuring safe, compliant, and highly reliable production performance
across assembly, testing, and automation cells.
Key Responsibilities
PLC, HMI, and Automation Systems
• Design, program, and troubleshoot Allen-Bradley PLCs, including advanced ladder
logic, function block, and structured programming.
• Develop and configure HMIs, motion control, drives, and industrial networks
(EtherNet/IP, DeviceNet, etc.).
• Integrate, calibrate, and troubleshoot sensors (proximity, photoelectric, analog,
displacement, temperature, pressure, etc.) used in precision automotive processes.
• Implement and optimize control logic for motors, conveyors, robotic interfaces,
pneumatics, and electromechanical systems.
• Support and maintain vision systems (Cognex, Keyence, or similar) including setup,
tool creation, part detection, inspection logic, and integration with PLCs.
• Provide daily production support, rapidly resolving controls-related issues
affecting cycle time, scrap, downtime, or quality.
Own and improve automotive processes involving leak testing, fastening
processes and vision-based inspection, presence verification, and
traceability
• Support prototype builds, pre-production runs, PPAP, and low-volume orders with
fast, flexible automation adjustments.
• Lead continuous improvement activities in automation, throughput, error-proofing,
and PFMEA-driven process robustness.
Controls Integration & Project Leadership
• Lead controls integration for new equipment, customer programs, model changes,
tooling upgrades, and retrofits.
• Execute full project lifecycle: concept development, vendor coordination,
programming, FAT/SAT, commissioning, and handoff.
• Collaborate with manufacturing, maintenance, quality, tooling, and launch teams to
ensure flawless execution and adherence to APQP requirements.
Documentation, Standards & Compliance
• Create and maintain electrical schematics, wiring diagrams, control panel
layouts, sensor calibration records, and standard work.
• Maintain technical documentation including PLC program backups, revision
control, change logs, drive configurations, and troubleshooting guides.
• Ensure all systems follow OSHA, IATF 16949, and customer-specific automotive
standards.
Maintenance Collaboration & Training
• Partner with maintenance to resolve recurring controls issues and implement
permanent corrective actions.
• Train and mentor maintenance technicians on PLC basics, ladder logic, HMI
navigation, sensor calibration, and root-cause troubleshooting.
Innovation, Technology Development & Continuous Improvement
• Evaluate, validate, and introduce new automation technologies (smart sensors,
IIoT/diagnostics, vision tools, advanced drive systems, etc.).
• Develop standardized controls strategies and processes that increase system
reliability, safety, and maintainability.
• Participate in internal/external training to stay current with emerging automotive
automation technologies.
Customer & Supplier Engagement
• Work with equipment suppliers, integrators, and automotive customers to address
technical challenges and optimize system performance.
• Support RFQs, customer change requests, process reviews, and launch readiness
activities.
Your.Contributions¿
• Bachelor"s.degree.in.Electrical? Controls?.or.Manufacturing.Engineering.(or.
equivalent.experience)¡
• 9 years.of.hands‗on.experience.with.Allen‗Bradley.PLCs.(ControlLogix?.
CompactLogix).and.RSLogix―Studio.❶666¡
• Experience.with.CAD―SolidWorks.is.a.plus¡
• Strong.troubleshooting.skills.in.a.high‗m i x ?.l o w ‗volume.manufacturing.environment¡
• Familiarity.with.industrial.networks.(EtherNet―IP?.DeviceNet).and.safety.systems¡
• Excellent.communication.and.cross‗functional.collaboration.skills¡ƒ