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Controls Engineer - Manufacturing Engineering
The Role
The Controls Engineer is a plant‑embedded, hands‑on engineering role supporting live Paint Shop manufacturing operations during off‑shift hours. This position is often the only controls engineer on shift and requires strong independent technical judgment to troubleshoot, stabilize, and improve production equipment with limited escalation support.
The role supports a mixed environment of conveyance and process‑driven systems, including automotive material handling as well as paint shop process equipment such as ovens, dip tanks, RTOs, sludge systems, and air supply house systems. In addition to off‑shift production support, the engineer will participate in planned shutdowns, downtimes, and model change activities, supporting project execution, upgrades, and long‑term reliability improvements.
What You’ll Do (Responsibilities)
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Provide hands‑on troubleshooting and support for PLC‑, drive‑, and network‑based manufacturing systems during 2nd‑shift production.
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Serve as the primary controls engineering escalation point for Skilled Trades during off‑shift events.
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Diagnose and resolve issues on automotive conveyance systems (e.g., skid, skillet, power‑and‑free, EMS/VAC).
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Support and troubleshoot paint shop process equipment, including ovens, tanks, fans, pumps, RTOs, sludge handling, and air systems.
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Troubleshoot and support Rockwell PowerFlex VFDs, motor starters, and related drive‑controlled equipment impacting throughput or process stability.
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Diagnose DeviceNet and EtherNet/IP communication issues affecting production systems.
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Support, troubleshoot, and modify Siemens HMIs programmed via TIA Portal, including alarm handling, visualization, and operator interface issues.
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Support and stabilize PID‑controlled processes, including temperature, airflow, pressure, and flow loops, in coordination with operations.
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Perform root‑cause analysis on recurring equipment or process failures and implement permanent corrective actions.
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Make sound risk‑based decisions during live production regarding intervention, containment, or deferral to dayshift.
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Support and execute controls projects during planned shutdowns, downtimes, and model launch activities, including installation support, integration, debug, and validation.
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Collaborate with Manufacturing Engineering, Maintenance, and Skilled Trades to improve equipment reliability, process stability, and maintainability.
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Maintain and update controls documentation, backups, and standards as required.
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Champion safety as the highest priority during all troubleshooting and project activities.
Your Skills and Abilities (Required Qualifications)
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3+ years of hands‑on experience supporting automated manufacturing systems in an automotive assembly environment.
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Advanced ability to program, troubleshoot, and modify Rockwell / Allen‑Bradley ControlLogix or GuardLogix PLCs in a production environment.
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Demonstrated hands‑on experience supporting automotive conveyance systems (e.g., skid, skillet, power‑and‑free, EMS/VAC).
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Experience troubleshooting process‑driven equipment such as ovens, thermal systems, pumps, fans, or air handling systems.
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Strong troubleshooting experience with Rockwell PowerFlex VFDs and motor starters.
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Working knowledge of PID control fundamentals and experience stabilizing temperature, airflow, pressure, or flow processes.
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Working knowledge of DeviceNet and EtherNet/IP industrial networks and associated diagnostics.
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Ability to read, interpret, and modify electrical schematics and controls documentation.
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Demonstrated capability to independently resolve complex, ambiguous production and process issues under time pressure.
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Must be able to work on a rotating/flexible shift (1st, 2nd or 3rd), as well as overtime and weekends, as needed.
What Can Give You a Competitive Edge (Preferred Qualifications)
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5+ years of prior automotive or manufacturing experience, particularly in Paint Shop environments.
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Bachelor’s degree in an engineering discipline.
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Experience serving as the primary or sole controls engineer on an off‑shift.
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Experience supporting or commissioning large‑scale conveyance systems.
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Experience supporting or tuning large process systems (ovens, RTOs, thermal or airflow‑based equipment).
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Working knowledge of GM controls standards (e.g., GCCH‑1, GCCS‑2).
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Experience with Fanuc robots or robot‑integrated systems.
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EPLAN experience or certification.
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Experience with vision systems (e.g., Cognex, VMT, Liberty Reach, Keyence).
