Sr Manufacturing Controls Engineer

Shift: 1st Shift

Working days: Mon - Fri

How will you make an impact?

The Senior Manufacturing Controls Engineer is responsible for leading and advancing Large Form Assembly (LFA) controls, automation, and manufacturing test development operations. This role provides senior-level technical leadership in PLC integration, HMI development, industrial networking, automated test system architecture, and system-level validation. This position serves as the controls and test development Subject Matter Expert (SME), ensuring automation readiness, control system robustness, and scalable test strategies across NPI, ramp, and sustaining production phases. The role drives PFMEA development, automation risk assessments, test coverage strategy, data acquisition architecture, and validation methodologies while aligning engineering documentation, software standards, and manufacturing execution to improve safety, quality, delivery, and cost performance.

What will you do?

• Lead the development, review, and control of controls and test manufacturing documentation including I/O lists, PLC architecture diagrams, network topologies, sequence of operations, test scripts, validation plans, SOPs, and software revision control.
• Conduct DFM and DFA reviews during NPI to ensure control systems and test architectures are optimized for manufacturability, serviceability, scalability, and repeatability.
• Develop, maintain, and update PFMEA documentation and structured risk assessments for control system integration and automated test processes.
• Architect and develop manufacturing test strategies including functional testing, interlock validation, automated sequence testing, and data capture methodologies.
• Design and develop PLC-based and PC-based automated test solutions for electrical, mechanical, and system-level validation.
• Define and standardize PLC programming structures, naming conventions, test logic sequencing, and revision control practices.
• Lead integration and validation of PLCs, HMIs, VFDs, sensors, instrumentation, safety devices, and communication protocols (Ethernet/IP, Modbus, BACnet, Profinet, etc.).
• Develop and optimize commissioning and test processes including power-up validation, I/O verification, safety interlock testing, leak/pressure validation support, and automated functional performance checks.
• Partner with Mechanical, Electrical, Industrial, and Quality Engineering to ensure comprehensive test coverage and cross-functional system integration.
• Develop automated data acquisition systems and ensure integration with MES and digital factory platforms for traceability and real-time performance monitoring.
• Provide advanced hands-on troubleshooting support for PLC logic faults, automation sequencing errors, instrumentation failures, communication issues, and test script gaps.
• Support FAT/SAT activities and customer validation events, ensuring test systems demonstrate reliability, repeatability, and compliance.
• Ensure controlled software documentation, test script management, and ECN discipline throughout NPI, ramp, and sustaining production phases.
• Drive continuous improvement initiatives focused on test coverage enhancement, automation reliability, cycle time reduction, and defect prevention.
• Serve as escalation point and technical mentor for junior controls engineers, test engineers, and automation technicians.
  
  

How will you get here?

Education:

• Bachelor’s Degree in Electrical Engineering, Controls Engineering, Mechatronics, Automation Engineering, or related discipline.
  
  

Experience:

• Minimum of 7–10 years of progressive experience in industrial automation, controls engineering, or manufacturing test development roles.
• Demonstrated experience developing automated manufacturing test systems and PLC-based validation platforms.
• Experience developing and maintaining PFMEA and automation/test risk mitigation documentation.
• Strong experience with PLC platforms (e.g., Siemens, Allen-Bradley, or equivalent).
• Hands-on experience with industrial networking, VFD configuration, instrumentation integration, and safety circuit validation.
• Experience developing structured test documentation including validation plans, coverage matrices, and standard work.
• Working knowledge of applicable safety standards (e.g., NFPA 70E, UL, ISO safety standards).
• Experience supporting NPI launches, production ramps, and sustaining operations.
  
  

Knowledge, Skills, Abilities:

• Advanced understanding of PLC programming methodologies, HMI development, industrial communication protocols, and control panel integration.
• Strong knowledge of motor controls, VFD configuration, safety interlocks, and power distribution integration.
• Experience creating and maintaining automation documentation including I/O lists, sequence of operations, and functional specifications.
• Familiarity with data acquisition systems and integration with MES or digital factory platforms.
• Experience performing structured root cause analysis for automation failures (8D, DMAIC, A3).
• Strong understanding of system-level commissioning, start-up validation, and automated test system integration.
• Ability to identify and eliminate non-value-added automation steps and improve overall equipment effectiveness (OEE).
• Excellent collaboration, communication, and documentation discipline in a fast-paced manufacturing environment.
• Ability to manage multiple programs while providing senior-level technical leadership across workcells.
  
  

Why Jabil

At Jabil, we believe in continuous innovation and operational excellence. The Manufacturing Controls Engineer will have the opportunity to work with cutting-edge automation technologies and contribute to large-scale manufacturing initiatives that drive reliability, safety, and efficiency across our operations. We foster a collaborative environment where diverse ideas are valued, technical expertise is developed, and career growth is supported through mentorship and hands-on project exposure.

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