Controls Engineer

Job Title: Controls Engineer
Job Description

The Controls Engineer maintains and supports automated production lines while providing technical direction to Maintenance personnel. The role focuses on PLC and robot programming and troubleshooting, manufacturing process improvements, and mechanical enhancements to tooling and equipment, ensuring all systems conform to customer requirements. The engineer works hands-on with automated equipment in a just-in-time environment, supporting both existing production and new line integrations, particularly within an automotive manufacturing setting.

Responsibilities

• Support production to ensure all equipment and control systems operate reliably, including troubleshooting equipment and systems to identify and correct root causes of issues.
• Program and troubleshoot I/O blocks, sensors, vision systems, barcode readers, Allen-Bradley and Siemens PLCs and HMIs, servos and servo drives, and FANUC robots.
• Configure, program, and troubleshoot electronic assembly tools and controllers to ensure consistent and reliable operation.
• Plan, schedule, conduct, and coordinate the technical and management aspects of assigned projects in collaboration with maintenance staff and outside vendors.
• Develop, evaluate, improve, and document manufacturing processes to enhance efficiency, quality, and reliability.
• Analyze manufacturing process flows on an ongoing basis to improve safety, quality, cost reduction, and throughput.
• Identify and analyze gaps in manufacturing processes and develop contingency plans to address equipment or system failures.
• Design and develop manufacturing processes for product enhancements, product changes, new products, and related fixtures and tooling that support zero-defect performance and low product cost.
• Assist in the preparation of engineering project proposals, including technical scope and implementation plans.
• Procure equipment and tooling essential to the effective operation of the department, ensuring alignment with technical and production requirements.
• Develop requests for quotation (RFQs), participate in vendor selection, prepare requisitions, and reconcile invoices related to engineering projects and equipment purchases.
• Ensure clear and effective engineering communication across maintenance, production, and external partners.
• Work closely with and provide direction to maintenance staff in a unionized environment to execute maintenance and improvement activities.
• Support integration and commissioning of new automated equipment and production lines, including EV-related lines, within an automotive facility.
• Contribute to continuous improvement initiatives by identifying opportunities to upgrade or optimize existing equipment and control systems.

Essential Skills

• 5+ years of experience in programming, maintenance, troubleshooting, and/or commissioning of automated equipment.
• Proficiency in Allen-Bradley PLCs, including programming, troubleshooting, and working within Rockwell Automation environments.
• Hands-on experience troubleshooting and maintaining mechanical equipment within an automotive manufacturing facility.
• Experience programming and troubleshooting Siemens PLCs and HMIs.
• Strong experience with FANUC robots, including programming and troubleshooting, with the ability to program from scratch when required.
• Experience integrating and configuring vision systems and barcode readers, including setup, inspection configuration, and troubleshooting.
• Experience with servos and servo drives, including setup, programming, and diagnostics.
• Proficiency in robotics troubleshooting and preventive maintenance for automated systems.
• Ability to develop, document, and improve manufacturing processes and process flows.
• Experience working with and directing maintenance staff, including in a unionized environment.
• Demonstrated project management experience in an industrial or manufacturing setting.
• Experience working in just-in-time (JIT) production facilities.
• Strong problem-solving skills with a focus on root cause analysis and continuous improvement.
• Ability to read, interpret, and modify control system documentation, including electrical schematics and PLC programs.

Additional Skills & Qualifications

• Experience with Cognex and/or Banner vision systems, including setup, programming, and inspection configuration.
• Experience with automated guided carts and rail guided carts used in assembly processes.
• Experience with collaborative robots and their integration into production lines.
• Familiarity with electronic assembly tools and controllers, including configuration and troubleshooting.
• Experience with process improvements in a high-volume manufacturing environment, particularly automotive.
• Exposure to EV production lines or similar advanced manufacturing programs.
• Ability to collaborate effectively with cross-functional teams, including production, maintenance, and external vendors.
• Strong written and verbal communication skills for documenting processes, preparing proposals, and coordinating engineering activities.

Work Environment

The role is based in a high-volume automotive manufacturing facility that operates on a just-in-time production model and is integrating new EV production lines. The Controls Engineer works closely with a tenured engineering and maintenance team and supports existing production lines as well as new line integrations. The position primarily follows a rotating shift schedule of Days and Afternoons (two-week rotation), typically 7:00 . to 3:00 . and 3:30 . to 11:30 ., with the expectation of flexibility to work midnight shifts as needed. The environment involves extensive hands-on work with automated equipment, including Allen-Bradley and Siemens PLCs, FANUC robots, servos, vision systems, barcode readers, and automated guided or rail guided carts. The facility emphasizes continuous improvement of existing equipment, allowing engineers to focus on optimizing processes and equipment performance rather than only reacting to faults. The work setting is industrial, with standard safety and PPE requirements typical of an automotive manufacturing plant. The organization offers a long-term opportunity with potential for extension or permanent employment based on performance, and provides overtime opportunities in accordance with applicable policies.

Job Type & Location

This is a Contract to Hire position based out of Windsor, ON.

Pay and Benefits

The pay range for this position is $38.00 - $45.00/hr.

Workplace Type

This is a fully onsite position in Windsor,ON.

À propos d'Actalent

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