Sr. Controls Engineer - Automated Guided Vehicles (AGV)

Rivian • Normal, IL

12d • Onsite

About The Position

The Controls Engineer is the production-line expert for controls and automation systems at Rivian’s facility in Normal, Illinois. The role combines PLC programming with strategic optimization of Automated Guided Vehicle (AGV) systems so the facility’s control logic and vehicle fleet work in synchronization. The engineer troubleshoots production issues and designs upgrades across Paint, Body, Battery, and General Assembly. This position reports to the Manager, AGV Maintenance and Repair.

Requirements

• 3–5 years of Controls Engineering experience or equivalent work experience.
• BS/MS in Electrical Engineering or equivalent work experience.
• Expertise with common controls hardware components used in high-volume manufacturing.
• Hands-on experience integrating and commissioning high-volume manufacturing equipment.
• Solid understanding of Wi-Fi 6, 5G private networks, and PROFINET/EtherNet/IP protocols.
• Experience with high-level managers, such as Daifuku, JBT, Dematic, or custom Python-based fleet controllers.
• In-depth knowledge of safety standards including ANSI/RIA 15.06 and OSHA, and industrial networking including Wi-Fi 6 and 5G private networks.
• Certified knowledge of ISO 3691-4 and ISO 13849 (Safety of Machinery).
• Experience participating in safety design reviews and validating equipment safety during buy-off.
• In-depth knowledge of electrical standards including NFPA 79, the National Electric Code, and UL 508A.
• Experience developing electrical schematics using EPLAN, AutoCAD Electrical, or similar tools.
• Experience writing standard and safety PLC projects from scratch for high-volume manufacturing equipment using Rockwell, Siemens, or Beckhoff PLCs.
• Experience creating HMI projects from scratch for high-volume manufacturing equipment using FactoryTalk View, WinCC, Ignition, Wonderware, TwinCAT HMI, or similar tools.

Nice To Haves

• Experience programming and troubleshooting industrial 6-axis robots such as Fanuc, ABB, or Kawasaki.

Responsibilities

• Participate in controls equipment buy-offs at vendor sites and Rivian’s Normal, Illinois factory, including FAT, SAT, and safety reviews.
• Contribute lessons learned and identified project gaps to the development of controls standards and specifications.
• Architect the interface between AGVs and FLP/SAP systems to automate replenishment triggers.
• Improve production lines and fleet battery cycles by reducing cycle time and downtime and improving quality.
• Develop and maintain traffic-control logic that prevents deadlocks and optimizes cycle time in alignment with Line Takt.
• Lead ISO 3691-4 validation, ensuring safety fields, laser scanner zones, and emergency circuits meet required performance levels (PLd/e).
• Design PLC-to-PLC communication protocols between AGVs and lineside equipment such as GFRs, lifts, and elevators.
• Serve as the Level 2 escalation point for AGV Technicians addressing system-wide logic errors or network dropouts.
• Develop technical SOPs for First Responders and define recovery methods for manual overrides in the Red Zone.
• Maintain, modify, and version-control equipment programs and fleet Master Config files, coordinating hardware, PLC, HMI, robot, and SCADA updates without disruption.
• Add or remove network devices and update network switch configurations as needed.
• Troubleshoot, improve, and add PLC features using Ladder Logic and/or Structured Text, with an emphasis on organized, structured, documented, maintainable, and reusable code.

Benefits

• Annual performance bonus and equity awards may be available to eligible candidates.
• Paid vacation and paid sick leave.
• Insurance benefits including life, medical, dental, vision, short-term disability, and long-term disability insurance for eligible employees.
• Opportunity to participate in Rivian’s 401(k) Plan, subject to eligibility requirements.
• Opportunity to participate in Rivian’s Employee Stock Purchase Program, subject to eligibility requirements.

What This Job Offers

• Job Type: Full-time
• Career Level: Mid Level