Controls Engineer

Position Summary

Ford Powertrain Manufacturing is seeking a skilled and hands-on Controls Engineer with 3 to 10 years of experience in a high-volume manufacturing environment. The role is responsible for improving, troubleshooting, validating, and supporting plant floor control systems, automation equipment, robotics, CNC/machining systems, data collection platforms, error-proofing systems, and industrial networks.

The successful candidate will work closely with production, maintenance, process engineering, safety, IT, suppliers, and plant leadership to improve equipment uptime, support engineering changes, resolve chronic downtime issues, and ensure robust controls integration across Ford Powertrain operations.

Required Qualifications

- Bachelor’s degree in Electrical Engineering, Electronics Engineering, Instrumentation Engineering, Controls Engineering, Automation Engineering, Mechanical Engineering, Mechatronics, or a related discipline.
- 3 to 10 years of controls engineering experience in a manufacturing, powertrain, automotive, machining, assembly, or industrial automation environment.
- Hands-on experience troubleshooting and modifying PLC logic, HMI screens, automation systems, robots, drives, sensors, actuators, and industrial communication systems.
- Experience with one or more PLC platforms such as Siemens, Rockwell/Allen-Bradley, Bosch, or equivalent industrial control systems.
- Working knowledge of robotic systems such as ABB, FANUC, or similar industrial robots.
- Ability to read and interpret electrical, pneumatic, hydraulic, controls, and automation prints.
- Understanding of industrial communication networks, fieldbus protocols, and plant floor data interfaces.
- Proficiency with Microsoft Office applications including Word, Excel, PowerPoint, and Outlook.

Preferred Qualifications

- Experience in Ford Powertrain manufacturing, machining lines, engine, transmission, eDrive, battery, or propulsion system manufacturing.
- Experience with CNC controls, machining cells, gantries, transfer systems, assembly lines, torque systems, and auxiliary automation equipment.
- Knowledge of Factory Information Systems, IIoT, error-proofing, QWX, QTS, WMA, OBL, SMART, VTAG, GPTS, QDAS, PDS, or similar manufacturing IT systems.
- Experience with vision systems such as Keyence, Cognex, Zebra, or equivalent inspection and traceability systems.
- Knowledge of RFID systems, traceability, complexity management, scheduling logic, and quality operating system strategies.
- Understanding of international and regional electrical and machine safety standards, including UL, ISO, IEC, risk assessments, PSS, and integrated safety systems.
- Experience with GPDS or equivalent program delivery processes, equipment launch, and manufacturing readiness deliverables.
- Lean Manufacturing, Six Sigma, 8D, FMEA, DMAIC, TQM, and Kaizen experience.

Technical Skills

Skill Area

Expected Knowledge / Experience

PLC and Controls Programming

Siemens, Bosch, or equivalent PLC platforms; logic troubleshooting, modification, validation, and backup management.

Robotics and Automation

ABB, FANUC, or similar robot systems; robot troubleshooting, path/program support, interlock validation, and automation fault recovery.

CNC and Motion Systems

CNC controls, machining cells, gantries, servo systems, drives, motion controls, and auxiliary equipment integration.

Vision and Traceability

Keyence, Cognex, Zebra, RFID, barcode, part tracking, complexity management, error-proofing, and quality data systems.

Manufacturing IT Integration

FIS, IIoT, QWX, QTS, WMA, OBL, SMART, VTAG, GPTS, QDAS, PDS, Andon, and plant floor data collection systems.

Industrial Networks

Fieldbus protocols, Ethernet-based industrial networks, communication architecture, device-level troubleshooting, and data interface validation.

Safety and Compliance

Machine safety, risk assessments, PSS, integrated safety, electrical standards, lockout concepts, and safety circuit validation.

Engineering Documentation

Electrical, pneumatic, hydraulic, controls, and automation prints; standards review; design review participation; lessons learned documentation.

Soft Skills and Competencies

Competency

Description

Problem Solving

Ability to break down complex equipment and controls issues into validated root causes and sustainable corrective actions.

Communication

Clear communication with production, maintenance, engineering, IT, safety, management, and supplier teams.

Ownership

Self-starting, self-directed, and accountable for delivering results in a fast-paced manufacturing environment.

Collaboration

Effective cross-functional teamwork across plant operations, technical teams, suppliers, and leadership stakeholders.

Continuous Improvement

Mindset to improve legacy processes, reduce downtime, standardize solutions, and apply lessons learned.

Technical Leadership

For experienced candidates, ability to guide troubleshooting, support design reviews, and coach junior engineers or plant technical personnel.

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