Automation and Controls Engineer

Caterpillar Inc.•Mapleton, IL

4d•$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 by applying 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 to increase productivity, improve equipment reliability, and support data-driven decisions. The position leads automation projects and capital projects from concept through design, installation, commissioning, validation, and operational handoff, and contributes to manufacturing strategy and digital transformation. The position 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. The stated summary pay range is $112,710 to $169,060.

Requirements

Bachelor’s degree in Automation Engineering, Mechatronics Engineering, Manufacturing Engineering, Electrical Engineering, or a related technical field.
Advanced knowledge of root cause analysis methods, 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 implement corrective and preventive actions.
Knowledge of manufacturing process optimization, Lean Manufacturing, Six Sigma, and continuous improvement principles.
Ability to monitor and interpret process metrics and familiarity with process validation, change management, process documentation, standard work, and best-practice deployment.
Experience leading automation, controls, digital manufacturing, or capital projects 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 for project updates, stakeholder expectations, and project execution.
Advanced knowledge of troubleshooting automation, controls, software, network, and equipment performance issues in manufacturing.
Experience diagnosing PLC, HMI, SCADA, robotics, industrial network, and control-system failures; analyzing logs, alarms, and performance data; and resolving issues across integrated manufacturing systems.
Ability to provide technical leadership during equipment startup, commissioning, and operational issue resolution.

Nice To Haves

Hands-on experience delivering Industry 4.0 or Smart Factory solutions in manufacturing.
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.
Project Management Professional (PMP) certification.

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, equipment modernization, and capital 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, data integration, and advanced analytics.
Integrate manufacturing systems with MES, ERP, cloud, and enterprise platforms in partnership with Operations, Engineering, and IT.
Manage 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 sustainable 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.