Controls Engineer - Senior

Job Summary

Develops, designs, implements, and supports automation and control systems for manufacturing equipment, machines, and production lines. Responsible for PLC programming, robotics integration, control system development, troubleshooting, commissioning, process optimization, and continuous improvement initiatives. Ensures reliable operation of automation systems while maintaining compliance with safety, quality, and operational standards.

Key Responsibilities

• Develop, modify, troubleshoot, and optimize PLC programs, robot logic, and automation control systems.
• Design end-to-end automation solutions for manufacturing equipment and production lines, including control philosophy, sequence logic, and safety architecture.
• Program and support Siemens S7-1500 PLCs and industrial automation systems.
• Configure, program, and troubleshoot ABB, FANUC, and Yaskawa robotic systems.
• Develop reusable software modules, function blocks, and standardized control architectures.
• Integrate robots, vision systems, conveyors, manipulators, servo drives, VFDs, safety PLCs, and other automation devices.
• Configure and maintain industrial communication networks including Profinet, Ethernet/IP, Modbus, and OPC UA.
• Design and improve HMI and SCADA systems, including dashboards, alarm management, data logging, and trend analysis.
• Support Industry 4.0 initiatives, predictive maintenance programs, and digital manufacturing solutions.
• Lead equipment installation, commissioning, Factory Acceptance Testing (FAT), Site Acceptance Testing (SAT), and production ramp-up activities.
• Perform root cause analysis using structured problem-solving methodologies such as 5 Why, Fishbone Analysis, Fault Tree Analysis (FTA), and implement permanent corrective actions.
• Conduct breakdown analysis and resolve complex automation, electrical, and controls-related issues to minimize downtime.
• Develop and execute preventive and predictive maintenance plans for automation equipment.
• Monitor and improve Overall Equipment Effectiveness (OEE), cycle time, throughput, reliability, and process efficiency.
• Validate and maintain machine safety systems, including LOTO procedures, interlocks, emergency circuits, guarding systems, and safety PLCs.
• Prepare technical documentation, project plans, equipment specifications, cost estimates, and engineering reports.
• Collaborate with production, quality, maintenance, suppliers, OEMs, and cross-functional teams to support manufacturing objectives.
• Coach, mentor, and provide technical guidance to junior engineers and technicians.
• Ensure compliance with Cummins Health, Safety, Environmental (HSE), quality, and manufacturing standards.

• 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.

• Experience in automotive, manufacturing, industrial automation, or robotics environments.
• Certifications or specialized training in PLC programming, robotics, SCADA, or industrial automation.

• Collaborates
• Communicates Effectively
• Customer Focus
• Drives Results
• Decision Quality
• Health and Safety Fundamentals
• Controls Engineering Knowledge
• Controls Networking
• Controls Safety
• Controls System Security
• Electrical System Troubleshooting
• Factory Automation and Control Systems
• Machine Programming
• Manufacturing Knowledge
• Sensor Technology and Measurement
• Self-Development
• Values Differences

• 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.

• Root Cause Analysis (RCA), Fault Tree Analysis (FTA), and structured problem-solving techniques.
• Strong analytical and decision-making abilities.
• Effective communication and stakeholder management skills.
• Collaboration and cross-functional teamwork.
• Project planning, execution, and coordination.
• Continuous improvement mindset and results orientation.
• Coaching, mentoring, and technical leadership capabilities.

• Intermediate level experience in controls engineering, factory automation, robotics, manufacturing systems, or related disciplines.
• Hands-on experience with PLC programming, industrial automation systems, and robotics integration.
• Experience supporting manufacturing equipment, production lines, and automation projects.
• Proven experience in troubleshooting complex automation and electrical control systems.
• Experience with commissioning, validation, process optimization, and continuous improvement initiatives is preferred.
• Exposure to Industry 4.0 technologies, predictive maintenance, and smart manufacturing solutions is advantageous.