Controls Engineer

Dana Incorporated•Louisville, KY

About The Position

The Controls Engineer designs, implements, and optimizes manufacturing processes to support efficient, cost-effective, high-quality production in an automotive environment. The role supports continuous improvement, resolves production issues, and works with cross-functional teams to introduce new products and technologies. It also ensures manufacturing processes comply with safety, environmental, and industry standards while advancing operational excellence. The position requires hands-on work with PLCs, robotics, and other production systems, as well as knowledge of electrical, mechanical, hydraulic, and pneumatic systems. The engineer provides technical support on the shop floor, develops process improvements, integrates new products into manufacturing, and maintains engineering and process documentation.

Requirements

Bachelor’s degree or at least 4 years of applicable experience.
Proficiency with Allen-Bradley and Siemens PLCs, including troubleshooting, programming, and documentation.
Proficiency with FANUC and ABB robotic systems, including troubleshooting, teaching, and programming.
Knowledge of production systems such as HMIs, barcode readers, and vision systems.
Knowledge of electrical, mechanical, hydraulic, and pneumatic systems, including automation control, AC and DC drives, mechanical drives and systems, sensors, and motor controls.
Strong understanding of automotive manufacturing systems, process engineering, and industrial automation.
Ability to analyze data, identify root causes, and implement effective solutions in a dynamic production environment.
Ability to manage multiple engineering projects, coordinate resources, and meet deadlines.
Excellent communication skills for working with production, quality, maintenance, and leadership teams.

Responsibilities

Troubleshoot, program, and document PLC control programs.
Troubleshoot, teach, and program robotic systems.
Work with engineering and maintenance to develop hardware and software solutions that improve plant safety, productivity, and quality and reduce scrap.
Collaborate across functions to meet project objectives for modifications to existing equipment and installation of new equipment.
Work with outside vendors to support successful project completion, and communicate vendor visits and outcomes to the maintenance manager.
Draw PLC, electrical, pneumatic, and hydraulic prints.
Develop and improve production workflows, layouts, and equipment utilization to enhance efficiency and reduce waste.
Provide technical support for process issues, equipment malfunctions, and quality concerns on the shop floor.
Apply lean manufacturing, Six Sigma, and other methodologies to drive process improvements and cost savings.
Work with engineering, quality, and production teams to integrate new products into manufacturing, including tooling, process validation, and documentation.
Ensure manufacturing processes meet safety, environmental, and regulatory standards.
Maintain documentation, including work instructions, process flows, and engineering change notices.