Senior Controls Engineer

This is a fully remote position, open to applicants in Michigan.

📋 Description

• Oversee the design, programming, commissioning, and validation of automated manufacturing machinery and control systems.

• Create and modify PLC, HMI, servo, vision, and robotic control programs.

• Facilitate new program launches and ensure that control systems comply with project timelines, quality, and production standards.

• Set process parameters, equipment controls, and monitoring systems.

• Diagnose and resolve electrical, control, automation, and process-related challenges.

• Collaborate with teams in manufacturing, quality, maintenance, product engineering, and suppliers.

• Conduct root cause analysis and implement corrective actions to address equipment downtime and quality issues.

• Develop and sustain electrical schematics, network architecture, PLC/HMI backups, process control plans, and equipment standards.

• Engage in PFMEA and manufacturing feasibility assessments.

• Assist in the sourcing, installation, validation, and startup of capital equipment.

• Educate maintenance and production staff on equipment operation, troubleshooting, and preventive maintenance.

• Promote continuous improvement focused on OEE enhancement, scrap reduction, cycle-time reduction, cost savings, and automation growth.

• Ensure adherence to safety, environmental, and customer specifications.

• Manage capital equipment projects from initial concept to launch.

• Provide support for equipment upgrades, troubleshooting, plant automation strategies, and new product introductions.

⛳️ Requirements

• Bachelor’s Degree in Electrical Engineering, Controls Engineering, Mechatronics Engineering, or a related technical discipline.

• 7–10 years of experience in controls engineering within a manufacturing setting.

• Experience in an automotive Tier 1 supplier environment is highly preferred.

• Background in automated assembly, injection molding, foam, or interior trim manufacturing processes is advantageous.

• Proficiency in PLC programming with Allen-Bradley, Siemens, and Rockwell.

• Experience with programming remote I/O using Rockwell/Balluff remote blocks.

• Familiarity with industrial robotics, particularly with FANUC and ABB.

• Knowledge of industrial networks such as EtherNet/IP, Profibus/Serial I/O, and IO-Link.

• Experience in electrical controls design and troubleshooting.

• Understanding of safety systems and machine safeguarding measures.

• Experience with dynamic robotic path planning.

• Knowledge of cybersecurity for OT environments, including safe deployment and management of NAT and VPN for tooling machines.

• Proficient in Allen-Bradley ControlLogix/CompactLogix, Siemens S7/TIA Portal, and Beckhoff TwinCAT.

• Knowledge of structured programming, sequencing, interlocks, and fault recovery techniques.

• Experience with AMRs/AGCs, Vidi, and Cognex Vision systems.

• Familiarity with digital twins, PLC simulation, robot simulation, and offline commissioning.

• Understanding of MES traceability.

• Programming skills in Python, C#, C++, or JavaScript.

• Knowledge of SQL, REST APIs, MQTT, OPC UA, and historian connectivity.

• Familiarity with Euromap Data Transfer, Ignition, and Power BI.

• Ability to thrive in manufacturing and production environments.

• Willingness to travel to plants, suppliers, and customer sites as needed.

• Capability to lift up to 25 pounds occasionally.

• Professional Engineer (PE) certification is preferred.

• Certified Automation Professional (CAP) is a plus.

• Experience with Industry 4.0 technologies, IIoT, and advanced manufacturing systems is preferred.

• Experience in supporting global manufacturing launches is advantageous.

🏝️ Benefits

• No specific benefits or compensation details provided.