Manufacturing Engineer

AprilAire•Village of Morrisville, NY

5d•Onsite

About The Position

The Manufacturing Engineer joins the team at the Madison manufacturing plant and manages manufacturing projects while serving as a key technical resource for daily operations. The role manages the design, procurement, installation, and implementation of automation, controls, equipment, and process improvement initiatives, balancing project priorities with operational support. The engineer serves as the onsite troubleshooting expert for complex equipment and manufacturing system issues escalated beyond Maintenance and Manufacturing Engineering Technicians, and drives sustainable solutions that improve safety, quality, productivity, and reliability. This position is 100% onsite at the Madison, Wisconsin Manufacturing Facility. The role includes designing, developing, programming, testing, debugging, implementing, and documenting PLC- and touchscreen-based automated controls. It also involves managing equipment projects from proposal and planning through installation and handoff, providing advanced troubleshooting and operational support, and collaborating with internal departments and vendors. The engineer may conduct basic mechanical and electrical research and development, fabricate components using machine shop equipment, and contribute to product design teams.

Requirements

Bachelor’s degree in manufacturing, mechanical, electrical, or controls engineering, or another closely related discipline, or an equivalent combination of education and experience.
At least 2 years of general manufacturing machine or process design experience to provide project accountability from concept through completion.
Valid driver’s license.
Knowledge of design techniques, tools, and principles used to develop automated control systems.
Knowledge of drafting standards.
Knowledge of machines and tools, including their designs, uses, repair, and maintenance.
Knowledge of circuit boards, processors, chips, electronic equipment, computer hardware and software, applications, and programming.
Knowledge of selecting, programming, implementing, and troubleshooting PLCs and user-interface touchscreens.
Ability to identify system performance measures and determine actions needed to improve or correct performance against system goals.
Ability to determine how a system should work and how changes in conditions, operations, and the environment will affect outcomes.
Ability to manage one's own time and the time of others.
Ability to arrange items or actions in an order or pattern according to specific rules.
Strong mathematical skills, including probability, statistical inference, plane and solid geometry, trigonometry, fractions, ratios, proportions, and selecting appropriate mathematical methods and formulas to solve problems.
Very strong problem-solving skills, including defining problems, collecting data, establishing facts, drawing valid conclusions, interpreting technical instructions in mathematical or diagram form, and working with abstract and concrete variables.

Responsibilities

Design, develop, program, test, debug, implement, and document PLC- and touchscreen-based automated control systems.
Develop and document control processes; select appropriate PLCs, touchscreens, sensors, user interfaces, servo mechanisms, motors, motor starters, variable frequency drives, and enclosures.
Develop control input/output lists and provide CAD documentation of conceptual control systems using sound engineering principles, current technology, and AprilAire documentation standards.
Manage fabrication of control systems and develop PLC and/or touchscreen code based on process requirements.
Develop training documents for Maintenance and Production Staff.
Manage equipment projects involving internal resources and/or outside contractors, from design and fabrication through programming and implementation.
Ensure equipment conforms to AprilAire standard components and programming specifications, applicable OSHA, ANSI, and NEC safety standards, project timelines and budgets, production needs, and AprilAire quality standards.
Document equipment and prepare the information required to turn it over to Production and Plant Maintenance; update Manufacturing Management on project status.
Manage activities of Maintenance Staff and/or Plant Engineering Technicians assigned to projects.
Propose manufacturing equipment projects by identifying needs, developing cost, timeline, resource, savings, and payback estimates, and submitting proposals to Manufacturing Management.
Serve as the highest-level controls and electrical troubleshooter before vendors are contacted; support and train Maintenance and Manufacturing Engineering Technicians in troubleshooting and root-cause analysis.
Troubleshoot automated control systems and electrical systems, including 480V three-phase, 230V three-phase, 240V, 120V, and 24VDC controls; at times, fully remediate root-cause failures without assistance.
Modify PC, PLC, and touchscreen software to support Plant Maintenance and Production Staff.
Identify and specify replacement components for obsolete or unavailable components and maintain records of modifications to existing automated control systems.
Collaborate with Design Engineers, Product Engineers, and other departments to maintain product quality and manufacturing efficiency.
Obtain information, services, and materials required for projects through liaison with vendors, including telephone contact, travel, or vendor visits.
Diagnose production problems and recommend solutions.
Keep informed about developments in machine design and controls, and conduct basic research and development on mechanical and electrical systems to improve equipment or process efficiency.
Safely fabricate components using machine shop equipment when cost effective; complete machines and devices, requisition parts, and assemble and finalize functional units.
Investigate new suppliers of parts, tools, and electrical components that may reduce costs.
Represent the Manufacturing Department on product design teams as assigned.
Recommend operational efficiencies, respond promptly to departmental concerns, and make safety a primary concern in all projects.