Advanced Manufacturing Engineer - Controls & Automation

GE HEALTHCARE•Milwaukee, WI

2d•Onsite

About The Position

This role provides automation engineering support for the X-Ray Tubes design and manufacturing facility in West Milwaukee, WI. The engineer will be responsible for the design, architecture, and implementation of automated equipment, including robotics integrated with existing systems. Key responsibilities include owning equipment controls standards, hardware programming, robot programming, commissioning, and project review, as well as auditing, installation, and safety assessments. The scope of automation processes covers assembly automation, collaborative robots (Universal Robots, Omron, Fanuc, ABB...), fixed automation, digital torque, visual inspection (2D & 3D), OEE, digital dashboards, Autonomous Intelligent Vehicles (AIVs), general automation technologies, and the integration of PLCs, HMIs, and motion systems. The candidate will also support initiatives by connecting physical processes to digital information. The role involves leading projects to implement automation in existing production lines and developing automated assembly for future lines to meet capacity needs. Experience in process-intensive manufacturing (e.g., machining, grinding, welding, precision assembly, brazing, casting, measurement, and testing) is preferred.

Requirements

BS/MS Electrical Engineering (or equivalent – Majors in: Controls and Computer Control Systems, Mechatronic Engineering, Automation Engineering, Software Engineering, Computer Science, etc.); or Associates degree in a technical discipline and a minimum of 6 years of experience in automation technologies.
2+ years of experience as a hands-on Controls Engineer or Applications Engineer working on automation and/or electromechanical systems.
Demonstrated program or project management skills of internal/external integrators.
Articulated robots experience.
Demonstrated experience owning production processes / growing capability in yield, quality, and capacity.
Proficiency with process integration and electromechanical / mechatronic systems.
Proficiency to troubleshoot PLC, Robot Application, and other critical programmable device issues.
Experience developing technical documents - ability to write / perform FMEA’s, Equipment Risk Assessments, ERS’s (Equipment Requirements Specifications) and/or other related processes.
Experience with controls automation design and safety standards; AutoCAD Electrical or equivalent, NFPA 79, RIA15.06, and/or other relevant industry standards.
Demonstrated troubleshooting, analytical, and planning skills.
Domain expertise in the automation and controls technologies field.
Experience with PLCs (GE Proficy, Allen Bradley ControlLogix, Siemens TIA Portal).
Experience with Safety PLCs (Allen Bradley ControlLogix, SIMATIC Safety Integrated, or Beckhoff TwinSAFE).
Human Machine Interface experience.
Experience with Field bus Networks (Ethernet IP, PROFINET, EtherCAT).
Familiarity with Electrical prints and standards for Industrial equipment.
In-depth knowledge of Electrical Standards (NFPA79, National Electric code, UL508A).
In-depth knowledge of Safety standards (ANSI/RIA15.06, OSHA).
Demonstrated excellence in programming PLCs. Must have a well-defined methodology for maintaining code structure and organization. Ability to program state machines for complex processes which involve multi-station parallel processing, pick and place automation, data acquisition, and PID control. Proven ability to design fault-tolerant systems with error handling and recovery.
Exposure to a wide variety of production machinery, industrial sensors, and equipment (LVDT and pressure transducers, dispense systems, temperature controllers, DC nutrunner torque controllers, current and power meters, etc).

Nice To Haves

Masters/PHD (or equivalent) in a technical concentration/field.
5-10 years’ experience in the design, build, programming, and deployment of automation.
Experience in the Electronics Assembly Industry.
Experience working with suppliers.
Knowledge and understanding of Quality Management Systems for document control, design transfer, verification, validation, and acceptance criteria for automation equipment in a regulated environment.
Mechanical design experience in automation equipment such as AutoCAD or Solidworks.
Substantial industrial experience in Mechanical or Manufacturing Engineering.
Six-sigma DMAIC & DFSS certified.
Experience with Vision systems implementation into manufacturing.
Experiences in Process Intensive manufacturing.
Solid working knowledge of GEHC QMS procedures for GMP.
Experienced developing tools and templates.
Experience working with global teams.
Ability to work independently across our diverse business and manufacturing lines.
Demonstrate strong communication skills (written and verbal) to all levels of the organization.
Ability to identify and implement Best Practices.
Willing to travel domestic and internationally up to 5% - 20% of the time.
Review, interpret, and modify electrical prints/schematics.
Experience programming Cartesian, SCARA and Articulated robots is highly desired (Fanuc, Kuka, Motoman, Epson).

Responsibilities

Support the manufacturing of internally built equipment, including programming, electrical/controls design, and documentation.
Research and aid in the development of manufacturing processes, including machine design and controls solutions to enhance operations.
Develop and participate in engineering projects for advanced engineering, providing engineering feasibility and support on high-complexity projects.
Design, build, commission, and validate machines and fixtures.
Assist with machine assembly, testing, and debug, including FAT/SAT, field-testing, and commissioning.
Support other engineers in designing and completing their projects.
Integrate robotics, vision, and/or automation into new and existing equipment.
Provide concise engineering project updates to project leaders and engineering teams.
Occasionally serve as a technical resource to troubleshoot problems with manufacturing teams and suppliers in areas of expertise.
Lead or support initiatives using Lean/Six Sigma tools for continuous improvement and cost reduction, and monitor performance metrics.
Conduct failure analyses, apply problem-solving techniques, and mentor others in critical thinking for root cause analysis and knowledge sharing.
Proactively communicate any concerns, problems, or technical decisions that impact the project to internal customers and/or the Project Engineer.
Review electrical drawings for proper wiring requirements, best layout, and component usage.
Program PLCs and HMIs using project-selected software (GE Proficy, Allen Bradley ControlLogix, Siemens TIA Portal).
Load programs and configure control components, then test controls to verify proper operation of equipment.
Design electrical control panels using SolidWorks Electrical.
Modify and update AutoCAD drawings from past projects.
Work with the operations and design team to help design for automation, define/develop automation concepts, work with key vendors/integrators to deliver cutting-edge solutions, and work with local teams to deploy automation into production.
Own and drive efforts to create standard controls Equipment/User Requirement documents.
Create training materials and provide technical training on automated controls process technologies.
Apply creative solutions and ideas to drive productivity and quality in manufacturing using key automation technologies like collaborative robots, AI, AIVs, and traditional automation techniques.
Update program backups for automation.
Reprogram automation for engineering changes, through-put, and quality improvements.
Select appropriate circuit protectors, wire and cable, sensors, safety hardware, PLC hardware, remote I/O, VFD, and servo systems.
Create detailed electrical and fluid schematics in CAD (AutoCAD Electrical preferred).
Program and tune variable frequency drives.
Program Cartesian, SCARA, and Articulated robots (Fanuc, Kuka, Motoman, Epson).