Controls EngineerThe Senior Controls Engineer is responsible for the design, development, implementation, and optimization of manufacturing control systems and automation solutions supporting automotive production operations. This role leads capital equipment projects from concept through launch, ensuring processes meet safety, quality, productivity, scrap, and labor objectives. The Senior Controls Engineer serves as a technical expert in PLC programming, robotics integration, process controls, and continuous improvement initiatives. This position also supports new product launches, equipment upgrades, troubleshooting, and plant automation strategies. This scope aligns with the existing IAC role description, which includes managing capital equipment processes, establishing controls, documenting processes, participating in PFMEA activities, and leading continuous improvement efforts.Essential ResponsibilitiesLead the design, programming, commissioning, and validation of automated manufacturing equipment and control systems.Develop and modify PLC, HMI, servo, vision, and robotic control programs.Support new program launches by ensuring all controls systems meet project timing, quality, and production requirements.Establish process parameters, equipment controls, and monitoring systems to maintain product quality and operational performance.Troubleshoot and resolve electrical, controls, automation, and process-related issues.Collaborate with manufacturing, quality, maintenance, product engineering,



and suppliers to improve equipment performance and process capability.Lead root cause analysis and corrective actions for equipment downtime and quality concerns.Develop and maintain controls documentation including:Electrical schematicsNetwork architecturePLC/HMI backupsProcess control plansEquipment standardsParticipate in PFMEA and manufacturing feasibility reviews.Support capital equipment sourcing, installation, validation, and startup activities.Train maintenance and production personnel on equipment operation, troubleshooting, and preventive maintenance.Drive continuous improvement initiatives focused on:OEE improvementScrap reductionCycle-time reductionCost savingsAutomation expansionEnsure compliance with all safety, environmental, and customer requirements.EducationBachelor's Degree in Electrical Engineering, Controls Engineering, Mechatronics Engineering, or related technical field.Experience7-10 years of controls engineering experience in a manufacturing environment.Automotive Tier 1 supplier experience strongly preferred.Experience supporting automated assembly, injection molding, foam,



or interior trim manufacturing processes preferred.Technical SkillsPLC Programming:Allen-BradleySiemensRockwellProgramming remote IO using remote blocks:Rockwell/BalluffIndustrial Robotics:FANUCABBIndustrial Networks:EtherNet/IPProfibus/SerialIO LinkElectrical controls design and troubleshootingSafety systems and machine safeguardingDynamic Robotic PathingCybersecurity for OT EnvironmentsKnowledge in how to safety deploy/manage NAT VPN Setup for Tooling MachinesAllen-Bradley ControlLogix/CompactLogix, Siemens S7/TIA Portal, Beckhoff TwinCAT; structured programming,sequencing, interlocks, and fault recoveryAMRs/AGCsVidi Cognex VisionSimulation and virtual commissioning: Digital twins, PLC simulation, robot simulation, and offline commissioning.MES TraceabilityPython, C#, C++, or JavaScriptSQL, REST APIs, MQTT, OPC UA, and historian connectivityEuromap Data TransferIgnitionPowerBICompetenciesStrong project management skillsExcellent analytical and troubleshooting abilitiesAbility to lead cross-functional teamsEffective written and verbal communicationCustomer-focused mindsetContinuous improvement orientationAbility to manage multiple projects simultaneouslyPhysical RequirementsAbility to work in manufacturing and production environments.Occasional lifting of up to 25 pounds.Ability to travel to plants, suppliers, and customer locations as required.Preferred QualificationsProfessional Engineer (PE) certificationCertified Automation Professional (CAP)Experience with Industry 4.0 technologies, IIoT, and advanced manufacturing systemsExperience supporting general manufacturing launchesKey Performance Indicators (KPIs)Equipment uptime/OEELaunch timing performanceScrap reductionProcess capability improvementsSafety performanceAutomation project completionManufacturing cost reductions#J-18808-Ljbffr

📌 Controls Engineer (Isla Guadalupe)
🏢 IAC Group
📍 Isla Guadalupe