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 (Ejido de la Finca)
🏢 IAC Group
📍 Ejido de la Finca