Sr. Automation and Controls Engineer

Sr. Automation and Controls Engineer

Requirements

• Bachelor’s degree in Controls Engineering, Electrical Engineering, Mechatronics Engineering, Automation Engineering, Robotics, or Computer Science. Equivalent industry experience may be considered.
• 6+ years of relevant experience in a manufacturing or engineering environment.
• Proven expertise in programming and troubleshooting Allen Bradley PLCs and HMIs (RSLogix 5000, RSLogix 500).
• Experience with Siemens SIMATIC PLCs.
• Demonstrated ability to program and integrate machine vision systems (required: Cognex 2D/3D; Keyence experience is a plus).
• Strong background in designing, programming, and deploying robotic and collaborative robotic systems.
• Proficiency in programming and troubleshooting Fanuc robots/cobots (EPSON and additional robotic platforms are advantageous).
• Competence in SQL database management, including interfacing with PLCs via RSSQL, FTTM (Factory Talk Transaction Manager), or Ignition.
• Knowledge of SQL programming and Stored Procedures.
• Experience designing and managing safety systems within an industrial setting.
• Familiarity with automotive product manufacturing (e.g., engine systems) is preferred.
• Basic knowledge of SAP and experience interfacing manufacturing systems with APIs; advanced SAP knowledge is a plus.
• Proficiency in Microsoft Office Suite (Word, Excel, PowerPoint, Outlook).
• Expertise with Ignition modules (Ignition Perspective, Transaction Groups, Vision, Database Connections, IoT integration, shopfloor device connections).
• Experience in process data collection via integrated systems.
• Capability to design and implement API connections using Python, Java, or MS.NET. (JSON, MQTT, RESTful, Web Services, etc.)

Responsibilities

• Collaborate with Manufacturing Engineers to design and enhance equipment and controls for new and existing products, focusing on cycle time reduction, quality improvement, and waste minimization.
• Lead initiatives to implement process automation using robots and collaborative robots, enhance shopfloor digitalization, and drive IoT initiatives for advanced process analysis and predictive maintenance.
• Champion the integration of machine learning and artificial intelligence to predict early machine failures and detect potential quality issues.
• Utilize Digital Twins for process modeling and real-time data for process optimization, including the development of dashboards and process analytics for comprehensive insights.
• Partner with Maintenance teams to troubleshoot equipment issues, minimize downtime, and oversee equipment relocation or modifications.
• Manage and maintain control programs (PLC, vision systems, robotics, databases, SCADA) utilized in the production process.
• Support the specification and installation of new equipment, ensuring comprehensive safety reviews and the integration of control systems with data collection platforms (e.g., SCADA, MES, ERP).
• Engage with equipment suppliers and contractors to oversee the installation and upgrading of production equipment.
• Lead and contribute to cross-functional teams across local and global operations to drive organizational goals.
• Ensure all design and implementation efforts adhere to ISO standards, RIA standards, OSHA regulations, and internal quality systems.
• Travel as needed to vendor locations for equipment inspections, tests, and installations.
• Maintain compliance with standard manufacturing practices and current control policies.
• Identify and resolve safety issues through proactive measures and corrective action implementation.
• Carry out other duties as directed or assigned.

Preferred Qualifications

• Familiarity with automotive product manufacturing (e.g., engine systems) is preferred.
• A minimum of 3 years of experience working with automated machinery in a manufacturing context is preferred.
• At least 1 year of project management experience, including cost justification, planning, and milestone management, is desirable.