Controls Engineering Specialist - Battery Pack Assembly

About the role

Location: Jeffersonville, IN (Remote to start, then On-site)

The Opportunity

As Engineering Specialist, Controls, you will help launch and run a new battery pack assembly plant. You will drive controls best practices, automation programming and equipment troubleshooting to hit safety, quality and production goals. You will play a key role in the design, installation, validation and continuous improvement of automated systems, covering PLCs, robotics, vision, fastening, welding and conveyors. You will work with IT, Manufacturing Engineering and production teams to solve problems, implement engineering changes, and capture lessons learned that shape future programs.

The role starts remotely and moves onsite in Jeffersonville, Indiana. During construction, you may attend onsite meetings or work from a temporary onsite office. It requires flexibility to work all shift schedules, including nights, weekends and holidays.

What You'll Do

• Ensure adherence to Key Unifying PRocesses (KUP), Safety Operating Systems (zero injuries), and Quality Operating System (zero defects) practices
• Use Andon and FIS (Factory Information Systems) data to prioritize work, monitor cycle times and drive 100% flow
• Identify, implement and train others on Controls Best Practices, Enablers and Change Control Processes
• Act as the liaison with IT on controls/IT interface issues, including integration with FIS, Error Proofing, QWX and QTS systems
• Review, approve and update engineering drawings; monitor software specifications and coordinate OEM training as needed
• Resolve issues during machine build, installation and production, including PLC programs, HMI screens and automation downtime
• Set up and maintain industrial barcode scanners and printers
• Run off equipment against supplier and plant specifications to validate capability, robustness and safety
• Support process design and FMEAs so production systems meet performance targets
• Coordinate installation timing and documentation with plant and Manufacturing Engineering teams
• Capture lessons learned and apply them to new programs and existing standards
• Program new installations and reprogram existing systems (vision, fastening, dispense, leak test, electrical test, welding, gantry, conveyor) for engineering changes and improvements
• Maintain automation program backups
• Lead troubleshooting for machinery, robots, automation and controls-related downtime
• Help train manufacturing personnel and plant electricians
• Review and coordinate project installations across the site

What You'll Bring

• Associate's degree
• 3+ years of controls engineering experience in an automated manufacturing environment
• 3+ years of networking and communication protocols experience
• 3+ years of PLC programming experience (Siemens and/or Allen-Bradley)
• Ability and willingness to work off-shift schedules

Nice to Have

• Bachelor's degree or higher in Engineering (Electrical, Mechanical, Controls or Automation preferred)
• Experience with FANUC, ABB and Universal Robots; Atlas Copco fastening; laser welding and metrology
• Knowledge of Industry 4.0 (data collection, AI/ML, IIoT, digital twin) and networking/controls architectures
• Familiarity with manufacturing IT applications such as plant information, traceability, quality data and statistical process control systems
• Understanding of Industrial Engineering, Lean/Six Sigma, 5S, Kanban, Poka-Yoke, Value Stream Mapping, 8D, FMEA, DMAIC, TQM and Kaizen
• Knowledge of data structures/algorithms and electrical/safety standards (UL, ISO, IEC), including risk assessments
• Direct experience with assembly and machining controls architectures (hardware and software)
• Ability to read electrical, pneumatic and hydraulic controls prints
• PLC programming knowledge (Siemens, Schneider, Bosch), plus CNC/motion control, vision and RFID systems
• Ability to troubleshoot PLC, CNC, robot and automation issues; CNC/gantry integration a plus
• Strong leadership, team-building and communication skills
• A self-starter with strong organizational and influencing skills, comfortable working with senior management, engineering, safety, IT and production

Compensation & Benefits

• The salary range for this position is $74,300 - $166,200.
• This position includes a comprehensive benefits package.
• Visa sponsorship is not available for this position.