Summary
The Senior Controls Engineer will provide technical leadership for electrical controls, automation, and plant systems within the manufacturing facility. This role is responsible for developing, maintaining, troubleshooting, and improving PLC, HMI, VFD, servo, robotics, vision, and industrial network systems that support safe, reliable, and efficient production. The Senior Controls Engineer will work closely with Engineering, Maintenance, Production, Quality, Safety, and external suppliers to improve equipment performance, support new product launches, reduce downtime, and advance automation and digital transformation initiatives.
Essential Duties and Responsibilities
- Lead the design, programming, implementation, troubleshooting, and continuous improvement of plant automation and controls systems.
- Develop, modify, and maintain PLC, HMI, VFD, motion control, servo, robotics, vision, and industrial communication systems.
- Provide advanced technical support to Maintenance and Production teams to resolve equipment downtime, repeat failures, process interruptions, and controls-related quality issues.
- Support new equipment installations, commissioning, process development, and new product launches from concept through start of production.
- Create, review, and maintain electrical schematics, control panel documentation, software backups, network drawings, machine safety documentation, and controls standards.
- Lead controls-related capital projects, upgrades, retrofits, and obsolescence plans, including scope development, supplier coordination, startup, validation, and training.
- Improve equipment reliability, uptime, cycle time, scrap reduction, operator usability, data visibility, and overall manufacturing performance.
- Ensure controls designs and modifications comply with applicable safety requirements, company standards, electrical codes, and industry best practices.
- Partner with Maintenance to develop troubleshooting guides, preventive maintenance tasks, spare parts strategies, and technician training for controls systems.
- Collaborate with Quality and Operations to support root cause analysis, mistake-proofing, process control, traceability, and data collection initiatives.
- Support plant digital transformation efforts including machine connectivity, production data collection, dashboards, SCADA/MES integration, and standardized automation practices.
- Mentor engineers, technicians, and maintenance personnel in controls troubleshooting, programming standards, and safe work practices.
- Communicate effectively with all levels of the organization to ensure issues are addressed and resolved in a timely manner.
- Conduct Layered Process Audits, per required schedule.
- Ensure compliance with all related IATF 16949 and ISO 14001 policies and procedures.
- Participate in plant-wide communications related to launch, process improvement, production support, and controls-related issues.
- Other duties as assigned.
- Bachelor’s degree in Electrical Engineering, Controls Engineering, Automation Engineering, Mechatronics, or a related technical field; equivalent experience may be considered.
- Minimum of 7 years of experience in industrial controls, automation, or manufacturing engineering, preferably in an automotive or high-volume manufacturing environment.
- Strong experience programming and troubleshooting PLCs, HMIs, VFDs, servos, motion systems, industrial networks, and machine safety systems.
- Demonstrated ability to diagnose complex electrical and controls problems involving sensors, actuators, motors, drives, panels, networks, machine logic, and production processes.
- Experience with Allen-Bradley/Rockwell Automation controls platforms preferred; Siemens or other controls platforms are a plus.
- Working knowledge of electrical schematics, control panel design, industrial power distribution, and applicable standards such as NFPA 70, NFPA 79, NEC, and OSHA requirements.
- Experience supporting machine vision, robotics, SCADA, MES, or plant data acquisition systems is preferred.
- Strong project management, documentation, analytical, and problem-solving skills.
- Ability to work collaboratively with cross-functional teams in a fast-paced manufacturing environment.
- Strong verbal and written communication skills.
Preferred Qualifications
- Experience in automotive manufacturing, textile, carpet, acoustic, thermal, or related production processes.
- Experience with AutoCAD Electrical, EPLAN, or equivalent electrical design software.
- Experience with Ignition, FactoryTalk, Wonderware, Kepware, SQL databases, or other SCADA/MES/data collection platforms.
- Experience developing standardized PLC/HMI code structures, reusable code blocks, and plant controls standards.
- Experience supporting digital transformation, machine connectivity, predictive maintenance, or real-time production performance monitoring.
- Lean Manufacturing, Six Sigma, or formal root cause analysis experience.
- Experience with Lean Manufacturing and Six Sigma methodologies.
Math Ability
- Ability to perform calculations related to electrical loads, timing, cycle rates, line speeds, sensor scaling, control loops, downtime analysis, and process capability.
- Ability to analyze production and equipment data to identify trends, root causes, and improvement opportunities.
- Strong math skills are required to handle complex calculations and problem solving.
Reasoning Ability
- Ability to define complex technical problems, evaluate alternatives, and implement practical solutions in a manufacturing environment.
- Ability to interpret technical instructions, electrical drawings, software logic, machine sequences, process data, and equipment manuals.
- Ability to make sound decisions under production pressure while maintaining safety, quality, and reliability requirements.
Computer Skills
- Proficient in Microsoft Office software.
- Proficient with PLC and HMI programming software such as Rockwell Studio 5000, FactoryTalk View, RSLogix, or equivalent platforms.
- Experience with drive configuration software, industrial networking tools, electrical CAD software, and data collection or SCADA platforms.
- MS Project, AutoCAD Electrical, Minitab, SQL, Ignition, or equivalent tools are a plus.
- Proficient in using engineering software and tools.
- Improve equipment reliability, uptime, cycle time, scrap reduction, operator usability, data visibility, and overall manufacturing performance.
- Ensure controls designs and modifications comply with applicable safety requirements, company standards, electrical codes, and industry best practices.
- Partner with Maintenance to develop troubleshooting guides, preventive maintenance tasks, spare parts strategies, and technician training for controls systems.
- Collaborate with Quality and Operations to support root cause analysis, mistake-proofing, process control, traceability, and data collection initiatives.
- Support plant digital transformation efforts including machine connectivity, production data collection, dashboards, SCADA/MES integration, and standardized automation practices.
- Mentor engineers, technicians, and maintenance personnel in controls troubleshooting, programming standards, and safe work practices.
- Communicate effectively with all levels of the organization to ensure issues are addressed and resolved in a timely manner.
- Conduct Layered Process Audits, per required schedule.
- Ensure compliance with all related IATF 16949 and ISO 14001 policies and procedures.
- Participate in plant-wide communications related to launch, process improvement, production support, and controls-related issues.
- Other duties as assigned.
Qualifications
- Bachelor’s degree in Electrical Engineering, Controls Engineering, Automation Engineering, Mechatronics, or a related technical field; equivalent experience may be considered.
- Minimum of 7 years of experience in industrial controls, automation, or manufacturing engineering, preferably in an automotive or high-volume manufacturing environment.
- Strong experience programming and troubleshooting PLCs, HMIs, VFDs, servos, motion systems, industrial networks, and machine safety systems.
- Demonstrated ability to diagnose complex electrical and controls problems involving sensors, actuators, motors, drives, panels, networks, machine logic, and production processes.
- Experience with Allen-Bradley/Rockwell Automation controls platforms preferred; Siemens or other controls platforms are a plus.
- Working knowledge of electrical schematics, control panel design, industrial power distribution, and applicable standards such as NFPA 70, NFPA 79, NEC, and OSHA requirements.
- Experience supporting machine vision, robotics, SCADA, MES, or plant data acquisition systems is preferred.
- Strong project management, documentation, analytical, and problem-solving skills.
- Ability to work collaboratively with cross-functional teams in a fast-paced manufacturing environment.
- Strong verbal and written communication skills.
Job Ad
Senior Controls Engineer – Autoneum North America, Inc. | Aiken, SC
Autoneum North America, Inc. is seeking a Senior Controls Engineer to join our Engineering team in Aiken, South Carolina. This is a hands-on technical leadership role for an experienced controls professional who enjoys solving complex manufacturing problems, improving equipment reliability, and driving automation improvements on the plant floor.
In this role, you will support and improve PLC, HMI, VFD, servo, robotics, vision, industrial network, and data collection systems across a manufacturing operation. You will partner closely with Engineering, Maintenance, Production, Quality, and Safety to reduce downtime, support new equipment launches, improve process control, and help advance plant automation and digital transformation initiatives.
What You Will Do
- Lead controls troubleshooting, programming, upgrades, and continuous improvement projects.
- Support equipment startups, commissioning, new model launches, and process improvements.
- Improve machine reliability, cycle time, operator usability, data visibility, and production performance.
- Develop and maintain controls documentation, software backups, electrical drawings, and plant controls standards.
- Mentor technicians and engineers in safe, effective controls troubleshooting and best practices.
What We Are Looking For
- 7 or more years of industrial controls, automation, or manufacturing engineering experience.
- Strong PLC, HMI, VFD, servo, electrical troubleshooting, and industrial network experience.
- Experience with Allen-Bradley/Rockwell Automation platforms preferred.
- Experience with vision systems, robotics, SCADA, MES, or plant data systems is a plus.
- Strong communication, documentation, project management, and problem-solving skills.
Why Join Us
You will play a key role in improving manufacturing performance, equipment reliability, and automation capability at the Aiken facility. This position offers the opportunity to lead meaningful technical improvements, work closely with cross-functional teams, and contribute directly to safe, efficient, high-quality production.
The primary purpose of this job description is to summarize the key/essential duties. Other duties may be assigned.
To perform this job successfully, an individual must be able to perform each essential duty satisfactorily. Reasonable accommodations may be made to enable individuals with disabilities to perform the essential functions.
Job Type: Full-time
Benefits:
- 401(k) matching
- Dental insurance
- Flexible spending account
- Health insurance
- Paid time off
- Vision insurance
Work Location: In person
