Manufacturing Systems and Controls Engineer

The Manufacturing Systems and Controls Engineer supports manufacturing development activities in the initial development and production of new products to provide input, data, and learnings to these stakeholders. This position will manage all control aspects of machinery and equipment to meet customer requirements – design, procure, build, and maintain prototype controls and equipment. 

 Responsibilities

• Lead efforts regarding the application of machine code throughout the plant.
• Lead troubleshooting of controls issues on machinery and equipment.
• Track and maintain all Programmable Logic Controller (PLC) codes.
• Lead efforts to upgrade and improve PLC controls and operations.
• Assist with Design for Assembly (DFA)/ Design for Manufacturing (DFM) reviews and help design/assemble tooling for upcoming product builds.
• Support bar code systems throughout the plant including
• Define barcode content and usage to support Data Collection.
• Deploy barcode readers and printers to support the Manufacturing process.
• Deploy MES functionality as needed including
• Error Proofing the manufacturing systems to eliminate scrap.
• Data definition.
• Data collection for Traceability, capturing the complete genealogy of each part.
• SQL Database creation, management, and population.
• Modification of PLC code to support data collection for traceability.
• Creation of work instruction screens to direct the operator in their duties.
• Integrate prototype assembly processes into the traceability Manufacturing Execution System (MES).
• Ensure Inspection, Testing, and Maintenance (ITM) requirements are met.
• Support process and machinery capability studies and equipment installations.
• Support validation of all new and modified processes.
• Assure compliance with ergonomic guidelines.
• Participate when required in Process Failure Modes and Effect Analysis (PFMEA) and work instruction reviews.
• Ensure that equipment meets all applicable industry standards.
• Identify and implement continuous improvement projects (e.g., cost reduction, efficiency improvement).
• Lead controls specification development for machinery and equipment.
• Assist with production startup and debugging at Springboro, Ohio as needed. 
• Support weekend work as required.
• Adhere to federal and state regulations.
• Adhere to all company policies, processes, and procedures.
• Performs other duties as requested, directed, or assigned.
• Predictable and reliable attendance.

Position Qualifications

• Bachelor’s degree in Electrical or Controls Engineering or equivalent experience.
• Minimum of seven (7) years of control engineering experience in a manufacturing facility.
• Working knowledge of PLC (Allen Bradley preferred), HMI’s, relays, contactors, servos, steppers, low voltage circuits, high voltage circuits, torque drivers, bar code systems, database storage, vision systems,
• Experience with quality management systems.
• Strong technical and communication skills.
• Experience with visual basic and bar code systems.
• Working Experience with machine electrical cabinet layout and machine controls.
• Experience with TS 16949 and ISO 14001.
• Computer skills including Microsoft Office, Rockwell, AutoCAD, Solidworks.

Key Competencies

• Focuses on Quality: Drives work results with a quality focus on actions and results.
• Decision Making & Analysis: Makes sound decisions based upon a mixture of data-driven analysis, expertise, experience, and judgment; collects relevant information, seeking input from others, and identifies connections and/or root causes of problems
• Continual Improvement: Displays a consistent orientation toward producing the highest quality products or services, while keeping a focus on sustainability. Constantly looking for incremental improvements in work processes and results.
• Working Safely: Demonstrates safe behaviors. Aware of potential risks and threats in the workplace.
• Delivers Results: Achievement oriented, feeling a sense of urgency to reach goals on time, if not before.
• Teamwork: Works cooperatively with others to accomplish team goals and organizational objectives.
• Communications: Exchanges thoughts, feelings, and information effectively.

Physical Requirements / Working Conditions

The physical demands described here are representative of those that must be met by an employee to successfully perform the essential functions of this job. Reasonable accommodations may be made to enable individuals with disabilities to perform essential functions.

• May be required to recognize small numbers, letters, symbols, colors on prints, and/or operate field instruments/equipment.
• Must work rotating shift schedule; may need to work overtime in emergencies.
• Able to complete physically demanding work.
• Able to lift and carry heavy objects.
• May be required to travel to and navigate a variety of sites to fully understand material needs.
• Must be able to manipulate equipment for calibration and modification.
• Prolonged periods of operating equipment.
• Excellent depth perception and reaction time.
• Visual acuity to follow hand signals, maintain logs, and inspect and maintain machinery.
• Able to work in confined spaces.
• Prolonged periods of kneeling, bending, crouching, and climbing ladders.
• Prolonged periods of standing, walking, bending, and stretching.
• Must be able to bend, lift, stretch, stoop, push, pull, stand, and carry as needed to inspect, service, and operate machinery, equipment, and gauges.
• Must work rotating shift schedule; may need to work overtime in emergencies.
• Must be able to maintain attention for long periods of time.
• Prolonged periods working on feet, using tools, and performing repetitive actions that entail frequent bending and stooping.
• Must be able to lift up to 35 pounds at a time.
• Visual acuity to read instructions, operate machines, and inspect parts produced.
• Must have good hand/eye coordination.
• Ability to maintain single task focus and situational awareness.
• Must be able to physically operate heavy equipment.
• Must be able to stoop, kneel, crouch, reach, and stand to operate and repair heavy equipment.
• The noise level in the work environment can be moderately loud.
• Ability to successfully complete position specific pre-placement requirements.