{"id":1604704,"url":"https://alion.io/job/one-manufacturing-controls-engineer","title":"Manufacturing Controls Engineer","company":{"id":25147,"name":"ONE","domain":"one.ai","url":"https://alion.io/company/one","size_band":"501-1000","is_staffing_agency":false,"employer_type":"direct","is_intermediary":false,"listed_via":null,"ats_vendor":"UltiPro","truth_index":{"grade":"B","score":75,"open_postings":3,"ghost_share":0,"stale_share":1,"repost_share":0,"time_to_fill_p50_days":null,"computed_at":"2026-10-17T05:46:00Z"}},"role":"Industrial Engineering","role_family":"Industrial Engineering","seniority":"senior","employment_type":"full_time","work_mode":"on_site","remote_scope":null,"remote_scope_basis":null,"remote_working_hours":null,"hiring_geo_confidence":"structured","locations":["Novi, United States"],"countries":["US"],"hiring_countries":[],"hiring_countries_total":0,"salary":null,"salary_estimate":{"min_usd":77000,"max_usd":145000,"period":"year","method":"role_seniority_country_remote_cell","sample_n":5578},"experience_years_min":5,"visa_sponsorship":false,"relocation_package":false,"has_equity":false,"technologies":[],"status":"live","first_seen_at":"2026-07-23T19:54:42Z","employer_posted_date":"2026-10-14","last_verified_at":"2026-10-17T09:09:26Z","board_verified":true,"closed_at":null,"days_open":85,"trust":{"level":"ok","repost_count":null,"flags":[],"days_open":85},"description":"ESSENTIAL DUTIES:\nAutomation & Controls Development\nDesign, program, and troubleshoot PLC-based control systems for automated manufacturing equipment.\nDevelop and maintain control logic using platforms such as Rockwell (Allen Bradley), Siemens, or similar PLC systems.\nConfigure HMI / SCADA systems for machine monitoring, diagnostics, and operator interface.\nDevelop and maintain automated production data collection, reporting, and diagnostic tools to support manufacturing performance.\nSupport manufacturing execution systems (MES), production traceability, and automation interfaces between PLCs and enterprise systems.\nIntegrate, troubleshoot, and optimize robotics, vision systems, and automated material handling equipment for high-volume production environments.\nEquipment Integration & Commissioning\nLead controls design, installation, and commissioning of new manufacturing equipment.\nCollaborate with equipment vendors and integrators during factory acceptance testing (FAT) and site acceptance testing (SAT).\nDevelop controls standards and documentation for plant automation systems.\nManufacturing Support\nProvide technical troubleshooting support for production equipment downtime related to controls, sensors, drives, vision, PLC, robotics, and automation.\nWork closely with maintenance and production teams to diagnose, resolve, and improve automation system performance. \nOptimize control strategies to improve cycle time, reliability, and equipment uptime.\nSafety & Compliance\nDesign and validate machine safety systems including safety PLCs, interlocks, emergency stops, and safeguarding systems.\nEnsure equipment complies with OSHA, NFPA, and relevant machine safety standards.\nSupport high-voltage and lithium-ion manufacturing safety requirements.\nProcess Optimization\nAnalyze equipment performance data to identify automation improvements and efficiency gains.\nImplement process automation improvements to increase throughput and reduce scrap.\nSupport continuous improvement initiatives and plant automation roadmaps.\nLead root cause investigations for automation-related production issues and implement sustainable corrective actions.\nDocumentation & Standards\nSupport, maintain, and enforce plant automation standards including programming architecture, documentation, naming conventions, and commissioning procedures\nMaintain detailed documentation including:\nPLC/HMI code change management revisions\nOpen issues management\nAutomation standardization\nElectrical schematics redlines\nQUALIFICATIONS:\nEducation\nBachelor’s degree in Electrical Engineering, Mechanical Engineering,Software Engineering, Mechatronics, or Automation Engineering\nExperience\n5+ years of controls engineering experience in a manufacturing environment\nExperience supporting automated production lines or industrial equipment\nExperience with PLC programming, Robotics, and industrial automation systems\nTechnical Skills:\n PLC programming\nAllen Bradley (Studio 5000 / RSLogix)\nSiemens (TIA Portal)\n HMI/SCADA systems\nIndustrial networking (Ethernet/IP, Profinet, IO-link, Modbus, OPC)\nServo systems and VFD drives\nRobotics integration (Fanuc, ABB, Kuka, or similar)\nMachine vision systems (Keyence, Cognex)\nElectrical schematics and panel design\nIndustrial sensors and instrumentation\nPreferred Experience\nEV battery, Automotive, Lithium-ion, Semiconductor, or High-tech manufacturing\nDry-room or clean-room manufacturing environments\nHigh-speed automated production lines\nSafety PLCs and machine safety standards (ISO 13849 / NFPA)\nAutomation troubleshooting and problem solving\nSystems integration and commissioning\nCross-functional collaboration\nContinuous improvement mindset\nStrong technical documentation skills\nAbility to support a fast-paced manufacturing environment","description_format":"text","description_chars":3770,"description_truncated":false,"requirements":{"experience_years_min":5,"management_years_min":null,"team_size_min":null,"manages_managers":false,"education":{"level":"bachelor","optional":false},"security_clearance":false,"languages":[]},"benefits":[],"hiring_locations":[],"hiring_excludes":[],"relocation_offered":false,"industries":["Energy & Utilities","Energy Storage"],"lifecycle":[{"event":"open","at":"2026-10-01T19:46:48Z"}],"visa":[],"liveness":{"score":17,"band":"cold","label":"Long shot","p_open":1,"p_active":0.621,"p_room":0.28,"age_days":85,"expected_fill_days":38,"reasons":["conf:4","win:tail","crowd:"],"computed_at":"2026-10-17T05:46:00Z"},"pay":null,"html_url":"https://alion.io/job/one-manufacturing-controls-engineer","json_url":"https://alion.io/job/one-manufacturing-controls-engineer.json","meta":{"generated_at":"2026-10-17T11:12:14Z","cache_seconds":300,"methodology":"https://alion.io/methodology","terms":"https://alion.io/terms","contact":"https://alion.io/contact","api":"https://alion.io/developers","about":"Alion is a live layer of people, companies and AI agents: who they are, whether they are real and active right now, what they do and how to work with them, readable by people and by agents and paid per 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