Controls EngineerLocation: Warren, Michigan, United States
Industry: Automotive Manufacturing
Role Type: Controls / Automation / MES Engineering
Position OverviewWe are seeking an experienced Controls Engineer to support a ground-up manufacturing automation implementation for a
major automotive manufacturer in Warren, Michigan.
This is primarily a
new-build development and implementation role, not a sustaining or maintenance position. The engineer will be responsible for designing, programming, integrating, and commissioning controls and manufacturing systems, with a strong focus on
Rockwell Studio 5000, Ignition, and PLC-to-MES integration.
The ideal candidate has personally taken automation systems from initial design through commissioning and production launch and can demonstrate hands-on experience developing PLC, HMI/SCADA, and MES functionality rather than only modifying or troubleshooting existing systems.
Key Responsibilities- Design and develop Allen-Bradley ControlLogix/GuardLogix PLC programs from the ground up using RSLogix 5000 / Studio 5000.
- Develop PLC architecture including ladder logic, tag structures, UDTs, AOIs, sequencing, diagnostics, alarms, and equipment interfaces.
- Design and build Ignition HMI/SCADA applications, including screens, tags, scripting, alarms, communications, and system configuration.
- Develop and implement communication between PLCs and MES systems.
- Create PLC/MES transaction and handshake logic for manufacturing operations.
- Support work-order verification, part and serial-number traceability, recipe/model management, production reporting, and pass/fail transactions.
- Integrate barcode scanners, RFID systems, and other production tracking equipment.
- Configure and integrate Zebra industrial label printers, including generation and implementation of ZPL code.
- Develop automated label-printing processes tied to production events, work orders, and cycle completion.
- Perform controls system startup, debugging, commissioning, FAT/SAT, and production launch activities.
- Troubleshoot PLC, HMI, MES, networking, and equipment communication issues as needed.
- Collaborate with manufacturing engineering, IT/MES teams, equipment integrators, and plant personnel throughout implementation.
- Develop and maintain controls documentation, system architecture, backups, and commissioning records.
Required Qualifications- Strong hands-on experience with Allen-Bradley ControlLogix/GuardLogix and Studio 5000 / RSLogix 5000.
- Demonstrated experience writing new PLC programs for equipment, stations, or production lines from scratch.
- Hands-on experience with Inductive Automation Ignition.
- Experience developing Ignition screens, tags, scripting, and/or application architecture.
- Experience integrating PLCs with MES or manufacturing information systems.
- Understanding of manufacturing transactions such as work-order validation, traceability, recipes, production reporting, and serial-number tracking.
- Experience commissioning automated manufacturing equipment.
- Strong troubleshooting skills across controls hardware, PLC software, industrial networks, and production systems.
- Experience in automotive or other high-volume discrete manufacturing environments.
Preferred Qualifications- Experience generating ZPL code and integrating Zebra industrial printers.
- Experience with barcode and RFID-based production traceability.
- Ignition Vision and/or Perspective development experience.
- Industrial networking experience including Ethernet/IP, OPC UA, SQL, or related communication technologies.
- Experience taking a controls project through the complete lifecycle: design 12 development 12 integration 12 startup 12 commissioning 12 production launch.
- Bachelor's degree in Electrical Engineering, Controls Engineering, Mechatronics, Automation, Industrial Engineering, or a related discipline.
Ideal CandidateThe strongest candidate will have experience
building controls systems from the ground up, including PLC programming, Ignition development, and PLC-to-MES integration.
This position is best suited for an engineer who has built and commissioned new manufacturing systems rather than someone whose background is primarily production support or maintenance.
