Manufacturing Systems and Controls Engineer

American Battery Solutions•Lake Orion, MI

3d•Onsite

About The Position

The Manufacturing Systems and Controls Engineer supports manufacturing development activities during the initial development and production of new products, providing input, data, and learnings to stakeholders. The role manages control aspects of machinery and equipment to meet customer requirements, including designing, procuring, building, and maintaining prototype controls and equipment. The position leads plant-wide machine-code application, controls troubleshooting, PLC code tracking and upgrades, and deployment of manufacturing systems such as barcode systems and MES functionality. It also supports tooling and process development, traceability, equipment installation and validation, production startup, capability studies, and continuous improvement. The role ensures equipment and processes meet applicable industry standards, ergonomic guidelines, ITM requirements, and regulatory and company requirements. The role is based at the Lake Orion location, with support for production startup and debugging in Springboro, Ohio as needed. Rotating shifts, weekend work as required, and overtime in emergencies may be necessary. The work environment can be moderately loud and includes physically demanding activities involving machinery, tools, equipment, and confined spaces.

Requirements

Bachelor’s degree in Electrical or Controls Engineering, or equivalent experience.
Minimum of seven years of control engineering experience in a manufacturing facility.
Working knowledge of PLCs (Allen Bradley preferred), HMIs, relays, contactors, servos, steppers, low- and high-voltage circuits, torque drivers, barcode systems, database storage, and vision systems.
Experience with quality management systems.
Strong technical and communication skills.
Experience with Visual Basic and barcode systems.
Working experience with machine electrical cabinet layout and machine controls.
Experience with TS 16949 and ISO 14001.
Computer skills including Microsoft Office, Rockwell, AutoCAD, and Solidworks.
Ability to complete position-specific pre-placement requirements.
Ability to meet the described physical requirements, including lifting up to 35 pounds, operating and manipulating equipment, working in confined spaces, and prolonged standing, walking, kneeling, bending, crouching, climbing, and repetitive work.
Ability to work a rotating shift schedule and overtime in emergencies; weekend work may be required.

Responsibilities

Lead efforts regarding the application of machine code throughout the plant.
Lead troubleshooting of controls issues on machinery and equipment.
Track and maintain all Programmable Logic Controller (PLC) codes.
Lead efforts to upgrade and improve PLC controls and operations.
Assist with Design for Assembly (DFA) and Design for Manufacturing (DFM) reviews and help design and assemble tooling for upcoming product builds.
Support plant barcode systems by defining barcode content and usage for data collection and deploying barcode readers and printers for manufacturing.
Deploy MES functionality as needed, including manufacturing error proofing, data definition and collection, traceability and part genealogy, SQL database creation and management, PLC code modifications for traceability data collection, and operator work-instruction screens.
Integrate prototype assembly processes into the traceability Manufacturing Execution System (MES).
Ensure Inspection, Testing, and Maintenance (ITM) requirements are met.
Support process and machinery capability studies and equipment installations.
Support validation of new and modified processes.
Assure compliance with ergonomic guidelines.
Participate in Process Failure Modes and Effects Analysis (PFMEA) and work instruction reviews when required.
Ensure equipment meets applicable industry standards.
Identify and implement continuous improvement projects, such as cost reduction and efficiency improvement.
Lead controls specification development for machinery and equipment.
Assist with production startup and debugging at Springboro, Ohio as needed.
Support weekend work as required.
Adhere to federal and state regulations and company policies, processes, and procedures.
Perform other duties as requested, directed, or assigned.
Maintain predictable and reliable attendance.

Benefits

Paid time off includes three weeks of vacation, up to 72 hours of sick time, 15 holidays, and parental leave.
100% company-paid medical, dental, vision, short-term disability, long-term disability, and life insurance.
Flexible Spending Account (FSA) and Health Savings Account (HSA) offerings.
Company-provided 401(k) savings plan with immediately vested matching contributions.
Voluntary benefits offerings.
Tuition assistance.
Employee Referral Program.
Employee development and career growth opportunities.
Comprehensive 100% employer-paid benefit plans for employees and their families.
Competitive salary and retirement program.