Work Model: This is a fully onsite role, with work performed at your designated Regal Rexnord office.
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The Controls Engineer is responsible for the design, implementation, troubleshooting, and continuous improvement of automation and control systems within the assembly plant. This role supports production by ensuring reliable operation of PLCs, HMIs, robotics, vision systems, drives, and associated electrical controls. The Controls Engineer works closely with production, maintenance, quality, and engineering teams to improve equipment performance, safety, quality, and operational efficiency.
Essential Duties and Responsibilities
Automation and Controls
- Design, program, modify, and maintain PLC, HMI, and SCADA systems.
- Configure and troubleshoot industrial networks and communication protocols.
- Develop and maintain electrical control schematics and documentation.
- Support startup, commissioning, and validation of new manufacturing equipment.
- Integrate robotics, vision systems, sensors, servos, and motion control systems into assembly processes.
Production Support
- Provide technical support for automated assembly equipment.
- Diagnose and resolve controls-related downtime issues.
- Perform root cause analysis and implement corrective actions.
- Support preventive and predictive maintenance activities.
- Participate in plant shutdowns and equipment upgrades as needed.
- Actively participate with the Process Engineer, Mechanical Engineer, and Leadership team on projects and continuous improvement.
Continuous Improvement
- Identify opportunities to improve equipment reliability and production efficiency.
- Lead improvement projects to increase throughput and reduce scrap; not just controls, but plant wide.
- Optimize machine cycle times and equipment performance.
- Lead and support lean manufacturing and continuous improvement initiatives.
Safety and Compliance
- Ensure control systems comply with company safety standards and applicable regulations.
- Support machine risk assessments and safety system validation.
- Maintain compliance with electrical and automation standards.
- Promote a safe work environment and participate in safety initiatives.
Project Management
- Manage automation projects from concept through implementation.
- Coordinate activities with equipment vendors, contractors, and internal stakeholders.
- Develop project schedules, budgets, and technical specifications.
- Track project progress and communicate status updates.
*all other duties as assigned
Qualifications
Education
- Bachelor's degree in Electrical Engineering, Controls Engineering, Mechatronics Engineering, or a related technical field.
- Equivalent combination of education and relevant experience may be considered.
Experience
- 3+ years of controls engineering experience in a manufacturing or assembly environment preferred.
- Experience with automated production equipment and industrial control systems.
- Experience supporting high-volume manufacturing operations.
Technical Skills
- PLC programming (Allen-Bradley, Siemens, Mitsubishi, or equivalent).
- HMI and SCADA development.
- Industrial robotics programming and troubleshooting.
- Motion controls, servo systems, VFDs, and motor controls.
- Industrial networking (EtherNet/IP, Profinet, DeviceNet, Modbus, etc.).
- Electrical schematic design and interpretation.
- Root cause analysis and troubleshooting techniques.
- Microsoft Office and engineering software applications.
Preferred Qualifications
- Experience in automotive or large-scale assembly manufacturing.
- Knowledge of machine vision systems.
- Experience with MES integration and data collection systems.
- Project management experience.
- Professional Engineer (PE) license or automation certifications are a plus.
Key Competencies
- Strong analytical and troubleshooting skills.
- Effective communication and teamwork.
- Project management and organizational abilities.
- Ability to work under pressure in a fast-paced manufacturing environment.
- Continuous improvement mindset.
- Attention to detail and commitment to quality.
Working Conditions
- Manufacturing plant environment with exposure to machinery, noise, and moving equipment. Plant is climate controlled with heat and a/c.
- Ability to walk production areas and work on the manufacturing floor for extended periods.
- Occasional lifting of up to 25 pounds.
- Ability to work flexible hours and respond to production emergencies when necessary.
Production is scheduled 4 ten hour days per week, with Friday overtime
Candidates must be eligible to work in the United States without requiring company sponsorship to obtain or keep U.S. work authorization.
Benefits- Medical, Dental, Vision and Prescription Drug Coverage
- Spending accounts (HSA, Health Care FSA and Dependent Care FSA)
- Paid Time Off and Holidays
- 401k Retirement Plan with Matching Employer Contributions
- Life and Accidental Death & Dismemberment (AD&D) Insurance
- Paid Leaves
- Tuition Assistance
