Automation and Controls Engineer

Caterpillar Inc.•Mapleton, IL

2d•$112,710 - $169,060•Onsite

About The Position

The Automation and Controls Engineer designs, implements, and optimizes advanced manufacturing technologies to improve safety, quality, delivery, and cost performance. The role advances automation, controls engineering, digital manufacturing, and Industry 4.0 initiatives using connected systems, robotics, data analytics, and smart factory technologies. Working with Manufacturing, Operations, Maintenance, Engineering, Information Technology, and external partners, the engineer delivers scalable solutions that increase productivity, improve equipment reliability, and enable data-driven decisions. The position leads automation projects, contributes to manufacturing strategy, and supports the development of smart manufacturing. It is onsite five days a week at Caterpillar’s Mapleton, Illinois facility and may require up to 10% travel. Domestic relocation assistance is available; visa sponsorship is not available.

Requirements

Bachelor’s degree in Automation Engineering, Mechatronics Engineering, Manufacturing Engineering, Electrical Engineering, or a related technical field.
Advanced knowledge of root cause analysis methodologies, including RCA, 5 Why, Fishbone, and FMEA.
Ability to analyze manufacturing, automation, and equipment performance issues using data-driven decision making.
Experience interpreting system data, performance metrics, and operational trends to identify root causes and drive sustainable improvements.
Ability to develop and implement corrective and preventive actions that improve equipment reliability and process performance.
Advanced problem-solving ability to independently resolve complex operational and technical challenges.
Knowledge of manufacturing process optimization techniques that improve safety, quality, throughput, and cost performance.
Experience applying Lean Manufacturing, Six Sigma, and continuous improvement principles.
Ability to monitor and interpret process performance metrics.
Familiarity with process validation, change management, and implementation of new manufacturing technologies.
Understanding of process documentation, standard work, and best-practice deployment.
Experience leading automation, controls, digital manufacturing, or capital projects from concept through implementation and operational handoff.
Knowledge of project planning, including scope, scheduling, resource coordination, budgeting, and risk management.
Ability to coordinate cross-functional teams, contractors, equipment suppliers, and system integrators.
Experience supporting project startup, commissioning, testing, validation, and performance verification.
Strong communication skills to provide project updates, manage stakeholder expectations, and drive execution.
Advanced knowledge of troubleshooting automation, controls, software, network, and equipment performance issues in a manufacturing environment.
Experience diagnosing and resolving complex PLC, HMI, SCADA, robotics, industrial network, and control system failures.
Ability to analyze system logs, alarms, and performance data to restore equipment functionality and minimize downtime.
Experience providing technical leadership and support during equipment startup, commissioning, and operational issue resolution.
Ability to work onsite five days a week at the Mapleton, Illinois facility; the position may require up to 10% travel.

Nice To Haves

Hands-on experience delivering Industry 4.0 or Smart Factory solutions in a manufacturing environment.
Experience implementing MES, IIoT, manufacturing analytics, machine connectivity, or cloud-enabled manufacturing platforms.
Knowledge of cybersecurity best practices for Operational Technology environments.
Experience with industrial robotics, autonomous material handling, 2D/3D machine vision, bin picking, motion control, or AI-enabled manufacturing solutions.
Experience developing electrical architectures, machine specifications, and controls standards for equipment builds and upgrades.
Lean Six Sigma Green Belt or Black Belt certification preferred.
Project Management Professional (PMP) certification preferred.

Responsibilities

Design, develop, program, commission, and support manufacturing automation systems, including PLCs, HMIs, SCADA, robotics, machine vision, industrial networks, and motion control technologies.
Lead automation, controls, and equipment modernization projects to improve safety, quality, throughput, reliability, and operational efficiency.
Troubleshoot and resolve controls, software, network, and equipment issues to minimize downtime and improve manufacturing performance.
Advance Industry 4.0 and digital manufacturing through machine connectivity, IIoT technologies, data integration, and advanced analytics.
Partner with Operations, Engineering, and IT to integrate manufacturing systems with MES, ERP, cloud, and enterprise platforms.
Lead automation and capital projects from concept through design, installation, commissioning, validation, and operational handoff, delivering on time and within budget.
Ensure compliance with machine safety, electrical, cybersecurity, and engineering standards, and provide technical guidance to manufacturing, maintenance, and engineering teams.
Lead root cause investigations and implement corrective actions to improve equipment reliability, process stability, and manufacturing performance.
Develop and maintain controls standards, electrical schematics, specifications, and technical documentation.
Collaborate with equipment suppliers, system integrators, and cross-functional teams.