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Manufacturing Controls Engineer

WKW North America LLC
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The Controls Engineer is responsible for maintaining, troubleshooting, and improving automation systems with a primary focus on PLCs, robotics, CNC equipment, and electrical controls. Daily activities include diagnosing electrical and mechanical issues, performing adjustments, and supporting production uptime. The role also participates in new equipment launches, from design through full integration, requiring both production‑floor and office‑based work.

 

Duties to include but not limited to:

Technical & Engineering Responsibilities:

  • Support maintenance, robotics, and engineering teams during machine downtime and troubleshooting events.
  • Diagnose and repair electrical systems, PLCs, VFDs, CNC machines, and 6‑axis industrial robots.
  • Design and implement cost‑effective equipment modifications to improve safety, quality, throughput, and reliability.
  • Develop Software Functional Specifications (SFS) and support software/hardware troubleshooting.
  • Research and implement innovative solutions to controls challenges across electrical, mechanical, and process specific areas
  • Identify weak points in automation systems to reduce downtime and prevent recurring issues.
  • Support engineering initiatives such as poka‑yoke and process improvements.
  • Participate in new machine launches, equipment installations, and system integrations.
  • Perform material handling or process control design, development, and troubleshooting.
  • Install, configure, and troubleshoot industrial vision systems.
  • Demonstrate strong PLC, HMI programming capabilities, including instrument setup and configuration.
  • Apply advanced electrical control principles and work with industrial communication networks (EtherNet/IP, Powerlink, EtherCAT, Profinet, etc.).

Collaboration & Communication

  • Collaborate with production, quality, maintenance, subcontractors, suppliers, and customers to resolve complex technical issues.
  • Communicate effectively at all organizational levels using modern communication tools.
  • Work cross‑functionally with professionals inside and outside the engineering discipline.
  • Interact successfully with customers at multiple levels within manufacturing environments.

Training & Leadership

  • Train maintenance staff in electrical and controls troubleshooting to improve technical capability.
  • Train production staff on machine setup and operation of automated equipment.
  • Work independently as a self‑starter capable of setting and achieving ambitious goals.

Professional Skills & Work Style

  • Demonstrate excellent verbal and written communication skills.
  • Perform effectively in fast‑paced, results‑oriented environments.
  • Manage multiple priorities, meet deadlines, and thrive under pressure.
  • Pursue continuing education in robotics, PLCs, VFDs, and CNC systems.
  • Use strong PC skills, including proficiency with Windows and Microsoft Office (Teams, Excel, Word, PowerPoint).

Authorization Level:

  • Able to stop production when controls related quality issues are present

Technical Knowledge & Skills

  • Extensive knowledge of electrical equipment, troubleshooting, and advanced electrical control principles.
  • Advanced understanding of control systems, preferably Siemens and Allen‑Bradley, with the ability to develop PLC programs.
  • Strong knowledge of frequency drives (Siemens, SEW, Allen‑Bradley).
  • Demonstrated HMI programming skills.
  • Ability to read and interpret electrical CAD drawings and blueprints.
  • Experience with industrial robots (ABB, Fanuc) is a plus.
  • Knowledge of advanced manufacturing processes.
  • Familiarity with Lean Manufacturing, Continuous Improvement, 5S, TPM, and related methodologies.
  • Understanding of QMS for IATF requirements and EMS for ISO 14001:2015 is a plus.

Hands‑On Technical Abilities

  • Run tests, isolate problems, configure and replace faulty components, install cables, and perform required technical tasks.
  • Troubleshoot and support both hardware and software systems in a manufacturing environment.

Experience Requirements

  • 3–5 years of experience in a manufacturing environment.

Interpersonal & Professional Skills

  • Strong problem‑solving skills.
  • Good interpersonal and communication abilities.
  • Ability to work effectively in a multicultural team environment with self‑motivation, responsibility, and proactive engagement.
  • Ability to train maintenance personnel and other team members.
  • Able to work independently, multitask, and manage time efficiently.
  • Consistently able to meet deadlines and manage multiple priorities.

Education

  • Bachelor’s degree in Electrical Engineering, Mechatronics Engineering, Controls Engineering, Automation Engineering, or a related engineering discipline required.
  • Associate degree candidates with significant experience in industrial automation, controls design, robotics integration, and PLC programming may be considered on an exceptional basis.
  • Relevant certifications in Siemens, Allen-Bradley, Fanuc, ABB, industrial networking, or automation systems are preferred.
  • Continuing education and advanced technical training in automation, robotics, and control systems is strongly encouraged.