Controls Engineer

Job Summary

The Controls Engineer is responsible for supporting and improving manufacturing automation systems to achieve safety, quality, delivery, and cost objectives. This role provides electrical maintenance and automation support through PLC programming, robotics integration, control system development, troubleshooting, commissioning, and process optimization. Working closely with cross-functional teams, the Controls Engineer ensures reliable and efficient operation of production equipment, drives continuous improvement initiatives, and maintains compliance with safety, quality, and operational standards. The position requires the ability to work independently with limited supervision and flexibility to support shift-based manufacturing operations as needed.

Key Responsibilities

Safety, Quality & Compliance

• Ensure compliance with Cummins Health, Safety, Environmental (HSE), quality, and manufacturing standards.
• Enforce Lockout/Tagout (LOTO), Permit to Work systems, machine safety requirements, PPE compliance, and safety PLC standards.
• Conduct risk assessments, safety audits, and machine safety validations, including interlocks, emergency circuits, and guarding systems.
• Promote 5S, housekeeping, and continuous improvement practices to maintain a safe and efficient work environment.

Controls Engineering & Automation

• Develop, modify, troubleshoot, and optimize PLC programs, robot logic, HMI/SCADA applications, and automation control systems.
• Design and implement end-to-end automation solutions, including control philosophy, sequence logic, and safety architecture for manufacturing equipment and production lines.
• Program, configure, and support Siemens S7-1500 PLCs, ABB, FANUC, and Yaskawa robotic systems.
• Integrate robots, vision systems, conveyors, manipulators, servo drives, VFDs, safety PLCs, sensors, and other automation devices.
• Configure and maintain industrial communication networks such as Profinet, Ethernet/IP, Modbus.
• Develop standardized control architectures, reusable software modules, and automation best practices.
• Support Industry 4.0, machine connectivity, predictive maintenance, cybersecurity, and digital manufacturing initiatives.

Equipment Reliability & Manufacturing Support

• Lead installation, commissioning, Factory Acceptance Testing (FAT), Site Acceptance Testing (SAT), and production ramp-up activities.
• Troubleshoot complex automation, electrical, robotics, hydraulic, and pneumatic system issues to minimize downtime and improve equipment reliability.
• Drive preventive, predictive, and corrective maintenance programs using CMMS systems such as MAXIMO.
• Conduct Root Cause Analysis using structured methodologies (5 Why, Fishbone, FTA) and implement sustainable corrective actions.
• Monitor and improve equipment performance through OEE, MTBF, MTTR, cycle time, throughput, and reliability improvements.
• Coordinate maintenance and automation activities with production, quality, suppliers, and OEMs to support manufacturing objectives.

Continuous Improvement & Project Management

• Identify and implement process optimization opportunities to improve productivity, quality, safety, and cost performance.
• Support capital projects through technical evaluation, cost estimation, appropriation requests, equipment specifications, and project execution.
• Lead cost reduction initiatives focused on maintenance efficiency, energy conservation, spare optimization, and waste elimination.
• Prepare technical documentation, engineering reports, control narratives, project plans, and operating procedures.

Team Leadership & Technical Development

• Provide technical leadership and hands-on support to technicians, trainees, and junior engineers across shifts.
• Coach, mentor, and develop team members to strengthen controls, automation, and troubleshooting capabilities.
• Lead shift meetings and maintenance reviews to communicate safety requirements, production priorities, and operational targets.
• Manage contractors and service providers to ensure work is completed safely, efficiently, and in compliance with company standards.

Planning & Resource Management

• Plan and manage critical spare parts inventory to support automation system reliability and business continuity.
• Track maintenance and automation performance metrics, ensuring achievement of uptime, reliability, quality, and cost objectives.
• Support resource planning and budgeting activities while driving continuous improvement in maintenance and automation performance
• Work in rotational shifts as per operational and business requirements.

Qualifications

• Bachelor’s degree in engineering, Automation, Electrical Engineering, Electronics Engineering, Mechatronics, STEM-related field, or equivalent experience.
• Intermediate level of relevant automation, controls engineering, or manufacturing experience. Equivalent engineering qualification with relevant Industry experience may also be considered.

Preferred Skills

• Experience in automotive, manufacturing, industrial automation, or robotics environments.
• Siemens S7-1500 PLC programming and troubleshooting.
• Robotics programming, teaching, commissioning, and troubleshooting (ABB, FANUC, Yaskawa).
• HMI and SCADA development and support.
• Automation and control system integration.
• Industrial networking technologies including Profinet, Ethernet/IP, Modbus, and OPC UA.
• Servo drives, VFDs, sensors, actuators, motion control, and control system hardware.
• PLC programming languages including Ladder Logic (LAD), Function Block Diagram (FBD), and Structured Control Language (SCL).
• Advanced troubleshooting of electrical and automation systems.
• Machine safety systems, Safety PLCs, LOTO, and industrial safety standards.
• Controls system cybersecurity and network architecture.
• Manufacturing process automation and continuous improvement methodologies.
• Certifications or specialized training in PLC programming, robotics, SCADA, or industrial automation.

Skills & Experience

• 10-12 years of hands-on Mechatronics maintenance experience, specifically with PLC’s and Assembly line machines.
• Siemens S7-1500 PLC programming and troubleshooting.
• Robotics programming, teaching, commissioning, and troubleshooting (ABB, FANUC, Yaskawa).
• HMI and SCADA development and support.
• Automation and control system integration.
• Industrial networking technologies including Profinet, Ethernet/IP, Modbus, and OPC UA.
• Servo drives, VFDs, sensors, actuators, motion control, and control system hardware.
• PLC programming languages including Ladder Logic (LAD), Function Block Diagram (FBD), and Structured Control Language (SCL).
• Advanced troubleshooting of electrical and automation systems.
• Machine safety systems, Safety PLCs, LOTO, and industrial safety standards.
• Controls system cybersecurity and network architecture.
• Manufacturing process automation and continuous improvement methodologies.