Controls Engineer - Senior

DESCRIPTION

The Senior Controls Engineer develops and supports all aspects of control systems, equipment, and manufacturing machinery. The role is responsible for designing, testing, implementing, troubleshooting, and optimizing control systems, while providing Level 2 and Level 3 support for CMES/Apriso across Asia and Europe. This position requires close collaboration with IE/3DX/Plant teams to deploy and sustain manufacturing processes designed in the 3D Experience environment.

Key Responsibilities Controls Engineering & System Development

• Develops, designs, and enhances industrial control systems, including PLC-based hardware and software.
• Conducts bench testing, functional testing, and validation of sensors, actuators, and system logic to ensure alignment with specifications.
• Creates, modifies, and maintains PLC programs and control architecture using Siemens/Rockwell platforms.
• Implements system upgrades, evaluates hardware/software performance, and supports overall manufacturing automation improvements.

• Provides Level 2 and Level 3 support for CMES deployments across Asia and Europe manufacturing sites.
• Works closely with business users and plant teams to troubleshoot CMES-related issues and suggest workarounds.
• Supports manufacturing sites in managing system downtime, high/low-value proliferation, and system behavior analysis.
• Executes CMES functional testing, training, and integration with plant equipment.

• Integrates OPC servers, PLCs, and plant systems with MES, ERP, and third-party applications.
• Supports connectivity solutions, data acquisition hardware design, and communication architecture.
• Applies knowledge of MQTT and other industrial communication protocols.

• Collaborates with IE/3DX teams to understand process design and ensure accurate execution at manufacturing sites.
• Investigates project requirements, recommends solutions considering cost, safety, personnel, and environmental factors.
• Prepares cost estimates, gathers equipment information, and assists in building appropriation requests.

• Troubleshoots complex electrical control system issues and restores systems to proper operating conditions.
• Identifies automation opportunities and implements enhancements to improve manufacturing efficiency.
• Coaches and mentors' junior engineers on controls engineering methods, tools, and safety practices.

• Controls Engineering (50%) - PLC programming, controls design, automation troubleshooting.
• Industrial/Manufacturing Engineering (30%) - shopfloor process understanding, Assembly/Machining experience.
• IT Skills (20%) - MES/CMES, interfaces, integration, queries.

• 5 to 10+ years shopfloor experience in Automotive Assembly, Machining, or Fabrication Domain.
• Strong background in controls programming, MES applications, automation systems, and plant system integration.

• PLC & Automation: Siemens / Rockwell (mandatory)
• Software & Tools: Java, PL/SQL, CMES / Apriso, ERP systems (mandatory)
• MES Downtime Management and traceability systems
• OPC communication, third-party system integration
• PLC architecture design and control hardware selection
• Awareness of MQTT protocol

• Functional + IT blended knowledge
• Experience with data acquisition systems, control hardware configuration
• Ability to design communication interfaces and machine-system connectivity

• College, university, or degree in STEM (Science, Technology, Engineering, Math) or related field, or equivalent experience required.