Senior Controls Engineer

IAC Group is seeking a Senior Controls Engineer to support automotive manufacturing operations through the design, development, implementation, and optimization of control systems and automation solutions. The role leads capital equipment projects from concept through launch, supports new product launches and equipment upgrades, troubleshoots production issues, and drives improvements in safety, quality, productivity, scrap, labor, and cost performance.

Responsibilities

Lead the design, programming, commissioning, and validation of automated manufacturing equipment and control systems

Develop and modify PLC, HMI, servo, vision, and robotic control programs

Support new program launches by ensuring all controls systems meet project timing, quality, and production requirements

Establish process parameters, equipment controls, and monitoring systems to maintain product quality and operational performance

Troubleshoot and resolve electrical, controls, automation, and process-related issues

Collaborate with manufacturing, quality, maintenance, product engineering, and suppliers to improve equipment performance and process capability

Lead root cause analysis and corrective actions for equipment downtime and quality concerns

Develop and maintain controls documentation including: Electrical schematics; Network architecture; PLC/HMI backups; Process control plans; Equipment standards

Participate in PFMEA and manufacturing feasibility reviews

Support capital equipment sourcing, installation, validation, and startup activities

Train maintenance and production personnel on equipment operation, troubleshooting, and preventive maintenance

Drive continuous improvement initiatives focused on: OEE improvement; Scrap reduction; Cycle-time reduction; Cost savings; Automation expansion

Ensure compliance with all safety, environmental, and customer requirements

Preferred

* Automotive Tier 1 supplier experience strongly preferred

* Experience supporting automated assembly, injection molding, foam, or interior trim manufacturing processes preferred

* Professional Engineer (PE) certification

* Certified Automation Professional (CAP)

* Experience with Industry 4.0 technologies, IIoT, and advanced manufacturing systems

* Experience supporting global manufacturing launches

Automotive Tier 1 experience

Automated assembly support

Injection molding experience

Foam manufacturing experience

Interior trim manufacturing

Professional Engineer certification

Certified Automation Professional

Industry 4.0 technologies

IIoT experience

Advanced manufacturing systems

Global manufacturing launches

Benefits

Remote work (any location)

Company

Automotive components and systems supplier to automakers worldwide

Southfield, Michigan, USA

https://www.iacgroup.com/

Founded in 2007

5001-10000 employees

Qualifications

* Bachelor's Degree in Electrical Engineering, Controls Engineering, Mechatronics Engineering, or related technical field

* 7-10 years of controls engineering experience in a manufacturing environment

* Strong project management skills

* Excellent analytical and troubleshooting abilities

* Ability to lead cross-functional teams

* Effective written and verbal communication

* Customer-focused mindset

* Continuous improvement orientation

* Ability to manage multiple projects simultaneously

* Ability to work in manufacturing and production environments

* Occasional lifting of up to 25 pounds

* Ability to travel to plants, suppliers, and customer locations as required

* PLC Programming:

+ Allen-Bradley

+ Siemens

+ Rockwell

* Programming remote IO using remote blocks:

+ Rockwell/Balluff

* Industrial Robotics:

+ FANUC

+ ABB

* Industrial Networks:

+ EtherNet/IP

+ Profibus/Serial

+ IO Link

* Electrical controls design and troubleshooting

* Safety systems and machine safeguarding

* Dynamic Robotic Pathing

* Cybersecurity for OT Environments

* Knowledge in how to safety deploy/manage NAT VPN Setup for Tooling Machines

* Allen-Bradley ControlLogix/CompactLogix, Siemens S7/TIA Portal, Beckhoff TwinCAT; structured programming, sequencing, interlocks, and fault recovery

* AMRs/AGCs

* Vidi Cognex Vision

* Simulation and virtual commissioning: Digital twins, PLC simulation, robot simulation, and offline commissioning

* MES Traceability

* Python, C#, C++, or JavaScript

* SQL, REST APIs, MQTT, OPC UA, and historian connectivity

* Euromap Data Transfer

* Ignition

* PowerBI

* Automotive Tier 1 supplier experience strongly preferred

* Experience supporting automated assembly, injection molding, foam, or interior trim manufacturing processes preferred

* Professional Engineer (PE) certification

* Certified Automation Professional (CAP)

* Experience with Industry 4.0 technologies, IIoT, and advanced manufacturing systems

* Experience supporting global manufacturing launches

* 7-10 years of controls engineering experience in a manufacturing environment.

Required skills

PLC Programming, Allen-Bradley ControlLogix/CompactLogix, Siemens S7/TIA Portal, Beckhoff TwinCAT, Industrial Robotics FANUC, Industrial Robotics ABB, Industrial Networks EtherNet/IP, Industrial Networks Profibus, Industrial Networks IO-Link, Electrical Controls Design, Machine Safeguarding, OT Cybersecurity, Cognex Vision Systems, MES Traceability, Simulation and Virtual Commissioning

Preferred skills

* Automotive Tier 1 supplier experience strongly preferred, * Professional Engineer (PE) certification, * Certified Automation Professional (CAP), * Experience supporting global manufacturing launches

Experience

7-10 years