Job Title: Automation Controls Engineer
Job Description
The Automation Controls Engineer identifies and delivers automation and process improvement opportunities across manufacturing operations, with a clear annual goal of generating substantial cost savings through automation and continuous improvement. This hands-on role designs, programs, and supports control systems, robotics, and vision systems while leading capital automation projects from concept through production. The position requires a technically strong, curious, and accountable engineer who thinks and acts like an owner, drives measurable results, and partners closely with cross-functional teams to modernize operations and strengthen manufacturing capabilities.
Responsibilities
- Identify and evaluate areas within the manufacturing process that can be automated, focusing on productivity, quality, and cost savings targets such as the annual $800K improvement goal.
- Design, program, and troubleshoot PLC-based control systems for manufacturing equipment and automated processes, including development of standardized control architectures and documentation.
- Develop, integrate, and optimize industrial robotic applications, including programming and supporting robots such as Fanuc and similar platforms.
- Design, implement, and maintain machine vision systems for inspection, validation, and process control, including Keyence and Cognex platforms or equivalent technologies.
- Integrate sensors, motors, actuators, servo systems, safety circuits, and HMI interfaces into robust, reliable automated solutions.
- Install, configure, and maintain a wide range of industrial sensors and automation devices, including SCHUNK sensors, SMC components, Banner sensors, proximity sensors, retroreflective sensors, fiber optic sensors, and light curtain sensors.
- Perform diagnostics on sensors and related control systems to ensure proper functionality and high equipment uptime.
- Design, update, and improve HMI screens to enhance operator usability, process visibility, and overall equipment effectiveness.
- Lead root cause investigations for automated equipment failures using structured, data-driven problem-solving methods and implement sustainable corrective actions.
- Develop automatic production and performance reports that support data-driven decision making and continuous improvement initiatives.
- Partner closely with Manufacturing Engineering, Operations, Quality, Supply Chain, Test, Certification, and Purchasing to support new product introductions and automation projects.
- Evaluate, recommend, and justify new automation technologies, robotics platforms, vision systems, smart sensors, and digital manufacturing tools, including determining return on investment.
- Lead capital equipment and automation projects from concept through specification, vendor selection, budgeting, scheduling, installation, validation, and production handoff.
- Drive continuous improvement initiatives that increase uptime, throughput, quality, and labor productivity, applying lean manufacturing and process improvement principles where appropriate.
- Champion cybersecurity and controls best practices for industrial automation systems to maintain secure and reliable operations.
- Provide technical mentorship, training, and support to maintenance and engineering teams on control systems, robotics, sensors, and new technologies.
- Operate, program, and troubleshoot control systems using Studio 5000 software and related vision systems.
- Read and interpret electrical schematics and control panel layouts, and use this knowledge to troubleshoot, optimize, and modify control systems.
- Manage project performance by setting clear deadlines and budgets, participating in weekly progress reviews, and ensuring on-time and on-budget delivery of development and automation projects.
- Continuously research emerging automation technologies, assess their business impact, and contribute to automation roadmaps aligned with operational and strategic objectives.
- Pilot and implement advanced technologies such as AI-driven inspection, smart sensors, and digital manufacturing tools, while simplifying and standardizing control systems to reduce complexity and long-term maintenance.
- Balance short-term operational needs with long-term technology investments to maximize value and maintain strong safety, quality, delivery, and cost performance from day one.
Essential Skills
- Bachelor’s degree in Electrical Engineering, Mechatronics Engineering, Robotics Engineering, or a closely related field.
- Minimum 3–5 years of experience in industrial controls and automation engineering.
- Approximately 5 years of experience programming PLCs such as Allen-Bradley, Siemens, or equivalent platforms.
- Approximately 5 years of hands-on experience integrating industrial robots such as Fanuc, ABB, KUKA, Universal Robots, or equivalent.
- Approximately 5 years of experience implementing and troubleshooting machine vision