Controls Engineer

Hutchinson•Grand Rapids, MI

10h

About The Position

ESSENTIAL DUTIES AND RESPONSIBILITIES: Automation & Controls Development · Design, program, and troubleshoot PLC-based control systems (e.g., Allen-Bradley, Siemens, Omron). · Develop HMI interfaces for operator interaction and real-time process visibility. · Implement new automation solutions to support new product introduction (NPI) and industrialization projects. · Integrate sensors, actuators, motion systems, robotics, and vision systems into automated equipment. Equipment & Process Support · Provide technical support for production equipment breakdowns and controls-related issues. · Improve equipment uptime by resolving root causes of automation failures. · Maintain and update electrical schematics, control logic documentation, and system backups. Project Engineering · Align with Assembly Engineering activities for equipment installations, upgrades, and process launches. · Manage project timelines, technical specifications, vendor interactions, and FAT/SAT execution. · Support process capability validation and ensure automation meets manufacturing requirements. Manufacturing Optimization · Analyze production data to identify trends and opportunities for cycle-time reduction, scrap reduction, and improved repeatability. · Implement continuous improvement initiatives using Lean manufacturing and Six Sigma methodologies. · Support poka-yoke (error-proofing) solutions through automation and sensor integration. Compliance & Safety · Ensure compliance with safety standards (e.g., NFPA 79, OSHA, CE, ISO). · Support risk assessments (FMEA, safety circuit design, lockout/tagout). · Develop and maintain control system standards, best practices, and work instructions. SUPERVISORY RESPONSIBILITIES: No Supervisory responsibilities. Refer to the Organizational Chart for detailed reporting structure.

Requirements

Experience in high-volume manufacturing or industrialization environments.
Hands-on experience with robotics (Fanuc, ABB, KUKA, UR).
Familiarity with MES/IIoT platforms and data collection systems.
Experience with CAD electrical design tools (AutoCAD Electrical, EPLAN).
Lean/Six Sigma training or certification.
Bachelor’s degree in Electrical Engineering, Controls Engineering, Mechatronics, or related field.
3+ years of experience in manufacturing automation, controls engineering, or similar role.
Demonstrated experience with PLC programming (Ladder Logic, Structured Text).
Knowledge of robotics, motion control, safety circuits, and industrial communication protocols (EtherNet/IP, Profinet, Modbus, etc.).
Strong troubleshooting skills for electrical, mechanical, and software-driven systems.
Advanced proficiency in Microsoft Excel. Experience with data dashboards.
Familiarity with automotive quality standards (IATF 16949, ISO 9001).
Lean Manufacturing in particular Value Stream Mapping
Ability to work in a manufacturing environment that may include exposure to heat, noise, dust, or chemicals.
Ability to stand, walk, or lift up to 50lbs.
Flexibility to support multiple shifts or off-hours operations, depending on business needs.

Responsibilities

Design, program, and troubleshoot PLC-based control systems (e.g., Allen-Bradley, Siemens, Omron).
Develop HMI interfaces for operator interaction and real-time process visibility.
Implement new automation solutions to support new product introduction (NPI) and industrialization projects.
Integrate sensors, actuators, motion systems, robotics, and vision systems into automated equipment.
Provide technical support for production equipment breakdowns and controls-related issues.
Improve equipment uptime by resolving root causes of automation failures.
Maintain and update electrical schematics, control logic documentation, and system backups.
Align with Assembly Engineering activities for equipment installations, upgrades, and process launches.
Manage project timelines, technical specifications, vendor interactions, and FAT/SAT execution.
Support process capability validation and ensure automation meets manufacturing requirements.
Analyze production data to identify trends and opportunities for cycle-time reduction, scrap reduction, and improved repeatability.
Implement continuous improvement initiatives using Lean manufacturing and Six Sigma methodologies.
Support poka-yoke (error-proofing) solutions through automation and sensor integration.
Ensure compliance with safety standards (e.g., NFPA 79, OSHA, CE, ISO).
Support risk assessments (FMEA, safety circuit design, lockout/tagout).
Develop and maintain control system standards, best practices, and work instructions.