What are the responsibilities and job description for the Controls Engineer position at W3Global?
Department: Engineering
Reports To: Engineering Group Leader
Position Summary
We are seeking a Controls Engineer responsible for the design, programming, integration, and continuous improvement of automated manufacturing systems across the facility. This role supports advanced stamping operations including large transfer presses, robotic welding systems, and automated inspection and leak testing equipment. The Controls Engineer plays a critical role in increasing equipment uptime, improving process capability, and driving plant-wide automation initiatives to support growth and operational excellence.
Core Responsibilities
Automation & Controls Engineering
Education & Experience
Reports To: Engineering Group Leader
Position Summary
We are seeking a Controls Engineer responsible for the design, programming, integration, and continuous improvement of automated manufacturing systems across the facility. This role supports advanced stamping operations including large transfer presses, robotic welding systems, and automated inspection and leak testing equipment. The Controls Engineer plays a critical role in increasing equipment uptime, improving process capability, and driving plant-wide automation initiatives to support growth and operational excellence.
Core Responsibilities
Automation & Controls Engineering
- Design, program, and troubleshoot PLC-based control systems (Allen-Bradley, Siemens)
- Develop and maintain HMI/SCADA interfaces for production equipment and operators
- Integrate robotics, automated welding cells, transfer press systems, and leak testing equipment into plant operations
- Support commissioning, startup, and validation of new automation equipment and capital projects
- Lead automation integration for new product launches
- Troubleshoot and resolve electrical, controls, and automation issues to minimize downtime
- Support high-tonnage stamping presses, transfer systems, and servo-driven equipment
- Maintain and optimize drive systems (ABB, Allen-Bradley, Indramat, Emerson, legacy systems)
- Work cross-functionally with Maintenance and Manufacturing Engineering to improve OEE, cycle time, and changeover efficiency
- Assist Maintenance with advanced electrical and PLC troubleshooting
- Analyze plant processes and implement automation and control improvements
- Identify and execute opportunities for increased efficiency, reduced scrap, and improved reliability
- Develop and implement preventative and predictive maintenance strategies for automated systems
- Standardize controls architecture and documentation across equipment
- Develop and deliver PLC and electrical training for maintenance personnel
- Provide technical guidance to Maintenance, Engineering, and Production teams
- Support skill development as the plant transitions to higher levels of automation
- Assist leadership with long-term automation strategy and capital planning
- Create and maintain electrical schematics, control prints, and system documentation
- Ensure compliance with National Electrical Code (NEC), IOSHA, and company safety standards
- Support quality systems by ensuring automation processes meet product and customer requirements
- Participate in pre-startup safety reviews and equipment validation
- Support Operations and Engineering Leadership on special projects
- Assist with design work using AutoCAD and/or Inventor
- Maintain a clean, safe, and organized work environment
- Stop production if safety or quality is at risk and escalate appropriately
Education & Experience
- Associate degree or higher in Electrical Engineering, Mechatronics, or related field preferred
- 0-8 years of experience in controls/automation within a manufacturing environment
- Strong background in automated systems, robotics, and stamping operations preferred
- PLC Programming: Allen-Bradley (required), Siemens (preferred)
- HMI/SCADA development
- Robotics integration (welding cells, material handling)
- Servo drives and motion control systems
- Electrical, pneumatic, and hydraulic system knowledge
- Ability to read and create electrical schematics
- Familiarity with AutoCAD and/or Inventor
- Problem Solving: Strong troubleshooting ability in high-pressure production environments
- Initiative: Self-directed with ability to lead projects and improvements
- Collaboration: Works effectively across engineering, maintenance, and production
- Adaptability: Thrives in a rapidly evolving, highly automated environment
- Time Management: Prioritizes effectively to support production needs and project timelines
- Work is performed in both office and manufacturing environments with regular exposure to:
- Automated machinery, robotics, and large stamping presses
- High noise levels and varying temperatures
- Electrical systems and moving equipment
- Proper PPE and adherence to all safety standards are required.