Sr. Controls Engineer

Cummins•Morristown, TN

4d•Onsite

About The Position

Cummins is seeking a Sr. Controls Engineer to join its Manufacturing team at the Cummins Drivetrain and Braking Systems Facility in Morristown, Tennessee. The role develops control systems, equipment, and machinery, with a focus on PLC-based automation that supports reliable, safe, and efficient manufacturing operations. The engineer leads controls design and implementation, troubleshoots production systems, develops testing and validation plans, and drives continuous improvement of control logic, software, and equipment configurations. The role also supports automation budgeting and capital requests, installation and startup of PLC systems, and the integration of automation into manufacturing operations. The engineer mentors less-experienced Controls Engineers and partners with Operations, Maintenance, Manufacturing Engineering, Quality, IT, and equipment suppliers. This position requires intermediate-level relevant work experience and extensive experience with Allen-Bradley and Siemens systems, Fanuc robots, automation safety, and the design, programming, and commissioning of automated cells.

Requirements

College, university, or degree in a STEM or related field, or equivalent experience.
Intermediate-level relevant work experience.
Extensive experience with Allen-Bradley and Siemens systems.
Background in safety as it relates to automation and automated cells.
Extensive knowledge of Fanuc robots.
Ability to design, program, and commission automated cells.
This position may require licensing for compliance with export controls or sanctions regulations.

Responsibilities

Lead the design, development, and implementation of PLC-based control systems to improve equipment reliability, manufacturing performance, and operational efficiency.
Troubleshoot and resolve controls, automation, and software issues to minimize downtime and maintain production system performance.
Develop and execute testing and validation plans for sensors, actuators, and control systems.
Modify control logic, software, and equipment configurations to improve safety, quality, productivity, and system capability.
Develop project budgets and capital appropriation requests for cost-effective automation solutions, and ensure investments deliver measurable business value.
Analyze manufacturing challenges and operational requirements and develop solutions that balance technical, economic, environmental, and workforce considerations.
Support the installation, startup, and optimization of PLC hardware and software systems and their integration into manufacturing operations.
Mentor less-experienced Controls Engineers and help develop organizational controls engineering capability.
Partner with Operations, Maintenance, Manufacturing Engineering, Quality, IT, and equipment suppliers to deliver automation solutions aligned with business objectives.
Communicate controls, networking, and automation requirements clearly to operators, technicians, leaders, and project stakeholders.
Identify electrical, hydraulic, pneumatic, and machine-control risks and incorporate safeguards, lockout/tagout requirements, and safe machine-design principles.
Design, review, and implement PLC, HMI, sensor, and automation systems that integrate with manufacturing equipment and enterprise systems.
Apply controls networking and system security knowledge to support equipment communications and protect control systems from cyber and operational risks.
Diagnose electrical, controls, and automation problems, restore equipment performance, and implement corrective actions to prevent recurrence.
Identify automation opportunities to increase productivity, improve quality, reduce downtime, and optimize manufacturing performance.
Develop machine programs, select sensor technologies, support process improvements, and implement solutions that improve safety, quality, delivery, and cost performance.
Design, program, and commission automated cells.