Controls Engineer 2

Overview: The Controls Engineer is responsible for creating, documenting, developing, supporting and improving upon the control systems that are essential to the production processes. Involvement will range from initial project sourcing all the way through SOP +90 days, or as required for corporate employees or launch through EOP plant employees (both may be required to support implementation of engineering changes for current production products). You will provide your controls expertise to help in tooling design and automation for new projects and process changes driven by product engineering changes. Provide support for Controls related issues, as required, to prevent or minimize production downtime. Help establish design goals, process and equipment specifications for Controls and Electrical power distribution systems. Benchmarks processes and equipment throughout the industry and incorporating into Piston Standards. Responsible for the planning, coordination, and implementation and tracking of assigned projects. This role will make minor operation decisions. Develop and track capital investment budgets for assigned projects. You will support Engineering Cost Estimator to supply quoted assumptions for the assembly. Works with the program team (internally and with the customer) to develop and launch products into production. Supports program meetings (both internally and with the customer) as required and/or requested. This Controls Engineer must possess a strong knowledge and understanding of EthernetIP & TCP/IP systems, DC Torque Systems (Tech Motive, Bosch, Atlas Copco) and Vision Systems (Cognex, DVT, Keyence) and a basic theory of industrial control systems. Provide guidance to Maintenance Technicians helping to develop skill-sets and strengthen the team as well as supporting the team during crisis management.You should be self-motivated and able to work with minimal direction, makes decisions independently, and is able to motivate others to complete the task at hand. The Controls Engineer is responsible for creating, documenting, developing, supporting and improving upon the control systems that are essential to the production processes. Involvement will range from initial project sourcing all the way through SOP +90 days, or as required for corporate employees or launch through EOP plant employees (both may be required to support implementation of engineering changes for current production products). You will provide your controls expertise to help in tooling design and automation for new projects and process changes driven by product engineering changes. Provide support for Controls related issues, as required, to prevent or minimize production downtime. Help establish design goals, process and equipment specifications for Controls and Electrical power distribution systems. Benchmarks processes and equipment throughout the industry and incorporating into Piston Standards. Responsible for the planning, coordination, and implementation and tracking of assigned projects. This role will make minor operation decisions. Develop and track capital investment budgets for assigned projects. You will support Engineering Cost Estimator to supply quoted assumptions for the assembly. Works with the program team (internally and with the customer) to develop and launch products into production. Supports program meetings (both internally and with the customer) as required and/or requested. This Controls Engineer must possess a strong knowledge and understanding of EthernetIP & TCP/IP systems, DC Torque Systems (Tech Motive, Bosch, Atlas Copco) and Vision Systems (Cognex, DVT, Keyence) and a basic theory of industrial control systems. Provide guidance to Maintenance Technicians helping to develop skill-sets and strengthen the team as well as supporting the team during crisis management.You should be self-motivated and able to work with minimal direction, makes decisions independently, and is able to motivate others to complete the task at hand. Responsibilities:

• Responsible for programming torque control systems and joint development. Selection of error and mistake proofing devices.
• Provide controls guidance in equipment selection, overall operations and future expansion. Integrating and networking PC's and PLC's (TCP/IP, EthernetIP)
• Analyze and calculate machine performance and requirements utilizing the PLC.
• Participates in the development of RFQ's and equipment specifications for capital and tooling requirements.
• Responsible for transferring all equipment and process documentation to the Production Plant prior to SOP. This includes all OEM Equipment Documentation (electronic and hard copies of Manuals, BOM, Drawings, recommended spare parts and recommended PM's) process requirements, capital / tooling investments and direct / indirect labor.
• Main interface with automation and capital equipment vendors for control solutions.
• Drive lean concepts (5S, OEE, Kanban, Visual Factory, TPM etc.) throughout the organization.
• Implement process improvements to improve overall efficiencies, including automation.
• Supports the APQP activities assigned through the Program Management group.
• Creates all controls related communication internally and externally, including technical presentation, design reviews, capacity analysis, and feasibility studies.
• Collaborates with Purchasing in evaluation of new suppliers, products and technologies to help maintain a competitive edge in the industry. Provide guidance in equipment and capital selection to the Purchasing Dept.
• Responsible for problem solving and resolution of issues at all sites as directed / or required.
• Corporate employees must be able to travel as required to support new launch, engineering change or production related activities (typically no more than 1-2 weeks at a time / estimated 6-12 weeks annually)

Qualifications: Bachelor's degree in Engineering, Instrumentation, Robotics, Computer Programming or a related field Four (4) years of experience as a Controls Engineer or a related role Four (4) years of experience with Robotic programming and controls Four (4) years of experience of PLC programming (Allen Bradley Micro Logic, SLC 500's, ControlLogix 5000 processors) for Manual Assembly Cells, Automated Assembly Cells and Power & Free conveyor systems. A minimum of four (4) years of experience working with the following: AutoCAD, RSLogix 5000, RSLogix 500, RS View, ex., Microsoft Word, Excel, Project, Power Point. Four (4) years of experience in HMI programming (AB PanelView and PanelView Plus) Four (4) years of experience with JIT, SPD, ILVS and Batch manufacturing systems. Including broadcast analysis from customer trigger through customer installation. Four (4) years of experience working with assembly requirements for all Automotive Component Systems; Body, Trim, Chassis, Powertrain, Interior and Electrical Systems. A minimum of four (4) years of experience working with manual and automated assembly systems and technologies, including both mechanical and control systems. A minimum of four (4) years of experience working with Industrial Safety Standards and requirements. L2 - A level 2 Employee has a high level of self-direction requiring minimal supervision. For significant projects, the supervisor will conduct a final check, with Employee, before action is taken. Expectations are that the Employee interacts frequently with other functional groups, customers, vendors, and can provide detailed analysis and fully implement solutions to resolve most issues independently. The Employee has extensive knowledge and skills required by the job description and skills matrix. Expectations are that the Employee develops, executes, and provides expertise in the development of projects involving the application of new technologies with significant technical risk. Additionally, the Employee helps define new standards based on working experience and supports the implementation of policy and procedure.