Controls Engineer

SUMMARY

This position will provide a combination of manufacturing engineering and electrical controls engineering services for new production equipment and all aspects of manufacturing to ensure that world-class products are available to our customers. This person will work independently with minimal supervision for most of the activities with a strong reliance on experience and good organizational skills. This person will act as a specialist and work with all levels of the organization. This position exists to improve efficiency, fix programming and mechanical related issues in a timely manner to reduce/ eliminate the equipment downtime. Their work affects equipment, employees, work environment and process standards and specifications.

RESPONSIBILITIES

• Assist new products team with determining requirements and cost estimates for machines that are built in-house and by outside suppliers. Ensure compliance of the GSS, Watertown machine specification for new acquisitions and retrofits.
• Designs, develops, tests, sources, cost justifies, and installs various tools, devices, modifications, fixturing, machinery and equipment for production to increase safety, throughput, quality, capacity, and reliability. Manage the completion of those projects from conception through evaluation, justification, purchase, and implementation.
• Lead projects, create timing plans, design control systems, create schematics, order components, write programs, debug machines and provide support after launch. 
• Coordinate with all levels of the organization to meet project timing and budget
• Integrate vision inspection, process monitoring, servo control, mechanical inspections, and other devices or processes into new and existing equipment. 
• Champion innovative techniques to improve manufacturing processes. 
• Develop, debug, and validate control systems including electrical, PLC, hydraulic, pneumatic, servo, HMI’s, etc. 
• Generate and implement standards and best practices – Logic, machine design, process, etc.
• Ensure that logic systems documentation is complete, up to date, stored in file structure, and available at all times. 
• Provide general supervision to outside contractors (electrical, mechanical, PLC programming, etc.) to resolve material and/or equipment problems, research and implement upgrades, new tools and operating procedures.
• Work with Operators, Supervisors, Maintenance and QA department to improve processes and troubleshoot equipment repair and maintenance. Support diverse portfolio of processes and controls hardware.
• Ensure proper training and guidance is provided to GSS Production team. 
• Apply Lean Mfg. / Toyota production system principles, IATF 16949, FMEA and Control plan concepts in controls engineering initiatives and tasks.
• Review existing logic programs to ensure safety of all associates and the processes are efficient & error proofed.
• Work closely with the Safety Team to ensure electrical controls and processes meet ergonomic and other safety standards.
• Champion continuous improvement projects to enhance safety, productivity, quality, reliability, capacity and processes. 
• Project manage & coordinate implementation of continuous improvement actions.
• Ensures manufacturing practices are current, consistent, and compliant with GSS Policies and Procedures, all external state/federal regulations and customer requirements.
• Demonstrate a leadership mindset holding themselves and their team to high standards to ensure timely and successful project execution. Encourage working cross functionally and collaboratively. 

The above are principal responsibilities and do not identify all duties inherent in the job

EXPERIENCE AND EDUCATION REQUIREMENTS

• BS Electrical, Mechatronics, Mechanical Engineering or equivalent
• Minimum of three years related to manufacturing experience in electrical, manufacturing, industrial engineering, or related field.

COMPETENCIES – KNOWLEDGE, SKILLS AND CHARACTERISTICS/BEHAVIORS

• Experience in manufacturing, quality, safety and management is essential. 
• Experience with Controls Systems including: Allen Bradley PLCs, Kinetix Motion Controls (Studio 5000 programming software), and HMIs (FactoryTalk Studio), GE PLCs (Proficy Machine Edition software), Siemens PLCs, and Robotics.
• Knowledge of ladder logic programming
• SQL, Database structure, Data collection systems.
• Diagnostic and troubleshooting skills. 
• Organizational and project management skills with the ability to prioritize and self-initiate when necessary.
• Knowledge of tool design, gage design, and fixture design.
• Computer skills include demonstrated knowledge of Microsoft office.
• Working knowledge of plant/facilities engineering, electronics, pneumatics and engineering controls.
• Excellent interpersonal, communication, organizational skills, and collaborative team player.
• Broad-base knowledge of Lean Manufacturing, including 5s, Kaizen, Kanban, Poke-a-Yoke, Process Mapping & Value StreamMapping, other tools & Techniques
• Strong analytical & problem-Solving Skills (Experience of proven techniques a plus ie. Shainin, DOE, 6 Sigma, 8D, 5 Why, etc.)
• Continuous Improvement mindset with ability to lead and influence others.
• Mechatronics experience and interests
• Python, Visual Basic (VBA), Ignition!, IIOT, I4.0 are a plus
• Experience with Controls Systems including: DirectLogic PLCs (DirectSoft programming software) knowledge is a plus, FANUC, ABB, and UR Robotics is a plus, Cognex vision systems is a plus
• Equipment development, tooling design, gage design, CAD (NX, AutoCAD) is a strong plus
• ISO 14001 and IATF 16949 experience is a strong plus.
• Knowledge of Automotive AIAG Core tools (FMEA, Control Plan, PPAP, MSA, SPC) is a strong plus

ADDITIONAL NOTES

• Able to lift up to 35 pounds. 

• Ability and Willingness to travel internationally

• Able to work in staggered or 2nd shift when necessary