Controls Engineer- Riverside, MO, USA

JOB DESCRIPTION

Job Summary

The Controls & Automation Engineer is responsible for developing, maintaining, troubleshooting, and optimizing automation and control systems that support the manufacturing and assembly of automotive seating and overhead systems. This role plays a key part in improving equipment reliability, productivity, quality, and operational efficiency through the implementation and support of advanced automation technologies.

The ideal candidate will have hands-on experience with PLC programming and troubleshooting, industrial automation systems, process improvement initiatives, and manufacturing equipment integration within a fast-paced production environment.

Essential Duties and Responsibilities

Continuous Improvement & Quality

• Participate in PFMEA development and risk assessment activities.
• Support Kaizen events, Lean Manufacturing initiatives, and continuous improvement projects.
• Identify opportunities to improve equipment efficiency, reduce downtime, and enhance product quality through automation solutions.
• Develop and implement error-proofing (Poka-Yoke) systems and automated quality controls.
• Participate in 8D problem-solving and root cause analysis activities.
• Investigate process abnormalities and implement corrective and preventive actions.
• Support data collection and analysis initiatives to drive operational improvements.

Engineering & Process Support

• Evaluate the impact of engineering changes on manufacturing processes and automation systems.
• Assist with equipment specifications, controls architecture reviews, and system design discussions.
• Review electrical schematics, controls drawings, and control system documentation.
• Support new equipment installations, equipment upgrades, and production line launches.
• Work closely with manufacturing, maintenance, quality, and engineering teams to improve process performance.
• Assist in equipment validation and commissioning activities.

Controls & Automation Responsibilities

• Program, troubleshoot, and maintain PLC-controlled manufacturing equipment.
• Diagnose and resolve issues related to PLC hardware, software, communications, and networked devices.
• Develop, modify, and optimize PLC programs to improve machine performance and reliability.
• Troubleshoot ControlLogix processors, ladder logic, structured text, and data handling functions.
• Maintain PLC documentation, version control, and backup systems.
• Support Human Machine Interfaces (HMI), industrial networks, and connected automation devices.
• Configure and troubleshoot:HMIs Barcode scanners Remote I/O systems Sensors and vision systems Relays and contactors Solenoids and pneumatic controls Variable Frequency Drives (VFDs) Servo systems and motion controls Industrial Ethernet networks
• Support automation projects involving machine integration, process automation, robotics, and material handling systems.
• Assist in commissioning and startup activities for new automated equipment.
• Collaborate with equipment suppliers and integrators during system implementation and troubleshooting.
• Apply electrical, instrumentation, and controls engineering principles to maintain and improve production systems.

Maintenance & Technical Support

• Provide technical support to maintenance personnel during equipment troubleshooting activities.
• Assist with troubleshooting pneumatic, hydraulic, electrical, and automation-related equipment issues.
• Develop and maintain preventive maintenance procedures for automation and controls systems.
• Support emergency troubleshooting efforts to minimize production downtime.
• Train maintenance and production personnel on automation systems and equipment operation when required.

Qualifications

To perform this job successfully, an individual must be able to perform each essential duty satisfactorily. The requirements listed below represent the knowledge, skills, and abilities required.

Education & Experience

• Bachelor's degree in Electrical Engineering, Mechatronics Engineering, Automation Engineering, or a related technical field preferred.
• Associate degree in Electrical Engineering Technology or related discipline considered with relevant experience.
• Minimum of 4-5 years of experience in Controls Engineering, Automation Engineering, Manufacturing Engineering, or a related industrial environment.
• Experience supporting automated production equipment in automotive or high-volume manufacturing environments strongly preferred.
• Experience with equipment startups, process improvements, and automation projects.
• Demonstrated experience troubleshooting complex manufacturing systems and reducing equipment downtime.

Technical Skills & Experience

Required

• Allen-Bradley PLC platforms
• Studio 5000
• ControlLogix systems
• PLC programming, troubleshooting, and diagnostics
• Electrical troubleshooting and controls systems support
• Industrial automation equipment and manufacturing processes
• Reading and interpreting electrical schematics and controls drawings

Preferred

• FactoryTalk View SE/ME
• Servo and motion control systems
• Vision inspection systems
• Robotics (Fanuc, ABB, KUKA, Yaskawa, or similar)
• VFDs and motor control systems
• Industrial networking (EtherNet/IP, DeviceNet, Profinet)
• Automated assembly equipment
• Industry 4.0 and smart manufacturing technologies
• SQL, manufacturing data collection, or SCADA systems

Key Competencies

• Strong troubleshooting and analytical skills
• Root cause analysis and problem-solving expertise
• Continuous improvement mindset
• Effective communication and teamwork
• Ability to manage multiple priorities in a fast-paced manufacturing environment
• Project management and automation implementation experience
• Strong attention to detail and commitment to safety and quality

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