Controls Engineer
The 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 Responsibilities
Lead 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 schematics
Network architecture
PLC/HMI backups
Process control plans
Equipment standards
Participate 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 improvement
Scrap reduction
Cycle-time reduction
Cost savings
Automation expansion
Ensure compliance with all safety, environmental, and customer requirements.
Education
Bachelor's Degree in Electrical Engineering, Controls Engineering, Mechatronics Engineering, or related technical field.
Experience
7-10 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 Skills
PLC Programming:
Allen-Bradley
Siemens
Rockwell
Programming remote IO using remote blocks:
Rockwell/Balluff
Industrial Robotics:
FANUC
ABB
Industrial Networks:
EtherNet/IP
Profibus/Serial
IO Link
Electrical controls design and troubleshooting




Safety systems and machine safeguarding
Dynamic Robotic Pathing
Cybersecurity for OT Environments
Knowledge in how to safety deploy/manage NAT VPN Setup for Tooling Machines
Allen-Bradley ControlLogix/CompactLogix, Siemens S7/TIA Portal, Beckhoff TwinCAT; structured programming, sequencing, interlocks, and fault recovery
AMRs/AGCs
Vidi Cognex Vision
Simulation and virtual commissioning: Digital twins, PLC simulation, robot simulation, and offline commissioning.
MES Traceability
Python, C#, C++, or JavaScript
SQL, REST APIs, MQTT, OPC UA, and historian connectivity
Euromap Data Transfer
Ignition
PowerBI
Competencies
Strong project management skills
Excellent analytical and troubleshooting abilities
Ability to lead cross-functional teams
Effective written and verbal communication
Customer-focused mindset
Continuous improvement orientation
Ability to manage multiple projects simultaneously
Physical Requirements
Ability 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 Qualifications
Professional Engineer (PE) certification
Certified Automation Professional (CAP)
Experience with Industry 4.0 technologies, IIoT, and advanced manufacturing systems
Experience supporting integral manufacturing launches
Key Performance Indicators (KPIs)
Equipment uptime/OEE
Launch timing performance
Scrap reduction
Process capability improvements
Safety performance
Automation project completion
Manufacturing cost reductions
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📌 Controls Engineer (Isla Guadalupe)
🏢 IAC Group
📍 Isla Guadalupe