Sr. Controls Engineer

We are looking for a talented Sr. Controls Engineer to join our team specializing in Manufacturing for our Cummins Drivetrain and Braking Systems Facility, in Morristown, TN.

The Sr. Controls Engineer develops all aspects of control systems, equipment, and machinery.

In this role, you will make an impact in the following ways:

• Lead the design, development, and implementation of PLC-based control systems that improve equipment reliability, manufacturing performance, and operational efficiency.
• Troubleshoot and resolve complex controls, automation, and software issues to minimize downtime and ensure critical production systems operate at peak performance.
• Develop and execute testing and validation plans that verify sensors, actuators, and control systems meet design specifications before deployment.
• Drive continuous improvement by modifying control logic, software, and equipment configurations to enhance safety, quality, productivity, and system capability.
• Deliver cost-effective automation solutions by developing project budgets, preparing capital appropriation requests, and ensuring investments generate measurable business value.
• Analyze manufacturing challenges and operational requirements to develop innovative solutions that balance technical, economic, environmental, and workforce considerations.
• Support the installation, startup, and optimization of PLC hardware and software systems, ensuring seamless integration into manufacturing operations.
• Mentor and develop less experienced Controls Engineers by sharing technical expertise, strengthening problem-solving capabilities, and building organizational controls engineering capability.

To be successful in this role you will need the following:

• Build strong cross-functional partnerships by working closely with Operations, Maintenance, Manufacturing Engineering, Quality, IT, and equipment suppliers to deliver automation solutions that support business objectives.

• Communicate technical concepts effectively by translating complex controls, networking, and automation requirements into clear, actionable information for operators, technicians, leaders, and project stakeholders.

• Lead with safety as the top priority by identifying electrical, hydraulic, pneumatic, and machine-control risks and incorporating appropriate safeguards, lockout/tagout requirements, and safe machine design principles into every project.

• Demonstrate strong controls engineering expertise by designing, reviewing, and implementing PLC, HMI, sensor, and automation systems that reliably integrate with manufacturing equipment and enterprise systems.

• Leverage controls networking and system security knowledge to ensure manufacturing equipment communicates effectively while protecting control systems from cyber and operational risks.

• Excel at troubleshooting and root cause analysis by quickly diagnosing electrical, controls, and automation issues, restoring equipment performance, and implementing permanent corrective actions to prevent recurrence.

• Drive factory automation and continuous improvement by identifying opportunities to increase productivity, improve quality, reduce downtime, and optimize manufacturing performance through advanced automation technologies.

• Apply manufacturing knowledge to deliver business results by developing machine programs, selecting appropriate sensor technologies, supporting process improvements, and implementing solutions that improve safety, quality, delivery, and cost performance.

Education, Licenses, Certifications:

• College, university, or degree in STEM (Science, Technology, Engineering, Math) or related field, or equivalent experience required.
• This position may require licensing for compliance with export controls or sanctions regulations.

Experience:

• Intermediate level of relevant work experience required.

Additional Requirements:

• Must have extensive experience in Allen Bradley and Siemens

• Background in safety as it relates to automation and automated cells

• Extensive knowledge of Fanuc robots

• Ability to design, program, and commission automated cells