Controls Engineer

Job Title: Controls Engineer Job Description
This role focuses on optimizing and supporting automated manufacturing systems by leveraging PLC data, robust troubleshooting, and advanced control technologies. The Controls Engineer analyzes and improves machine performance, leads root cause investigations, and implements error-proofing solutions to enhance quality, safety, and efficiency. The position collaborates closely with maintenance, production, and automation vendors to support new equipment launches, maintain existing systems, and drive continuous improvement across a fast-paced automotive manufacturing environment.
Responsibilities
- Analyze and optimize machine performance using PLC data to improve throughput, quality, and reliability.
- Lead root cause analysis for systemic and intermittent equipment and process issues, and implement sustainable corrective actions.
- Select and integrate error-proofing and mistake-proofing devices to address quality concerns and reduce defects.
- Understand, configure, and maintain machine Ethernet networks to ensure reliable communication between devices and systems.
- Conduct regular audits of safety control programs and safety devices to ensure compliance and safe operation of equipment.
- Plan, coordinate, and implement assigned automation and controls projects from concept through completion.
- Interface with automation and capital equipment vendors to specify, integrate, and support new and existing systems.
- During new equipment launches, transfer all equipment and process documentation to the production plant prior to start of production, including OEM manuals, bills of materials, drawings, recommended spare parts, and preventive maintenance plans in both electronic and hard copy formats.
- Lead activities related to new product and process manufacturing and recommend design and process improvements for manufacturability and reliability.
- Develop preventive maintenance programs in collaboration with plant management to improve uptime and extend equipment life.
- Support controls-related issues on the production floor to minimize downtime and maintain stable operations.
- Guide and mentor maintenance technicians to develop their controls skillsets and strengthen the overall technical team.
- Ensure peak efficiency and safety of all manufacturing machinery and equipment through continuous monitoring and optimization.
- Assist in the installation, commissioning, and maintenance of machines, tools, and automation systems.
- Analyze equipment requirements and assist in the requisition of tools, spare parts, and components necessary for reliable operation.
- Identify and recommend efficiency improvements in processes and equipment to reduce costs and improve productivity.
Essential Skills
- Bachelor's degree in Engineering, Instrumentation, Robotics, Computer Programming, or a related field.
- Minimum of 2 years of experience as a Controls Engineer or Maintenance Technician.
- Experience maintaining robots in production processes.
- Experience working with Just-In-Time (JIT), in-line vehicle sequencing (ILVS), and batch manufacturing systems.
- Strong knowledge of manual and automated assembly systems and technologies, including both mechanical and control systems.
- Hands-on PLC programming experience (24 years), particularly with Allen-Bradley ControlLogix 5000 processors using Studio 5000 Logix Designer.
- Proficiency in HMI programming (24 years), including FactoryTalk View Studio and PanelView Plus.
- Proficiency in vision systems programming (24 years), including Cognex and Keyence platforms.
- Ability to troubleshoot complex controls, electrical, and automation issues in a production environment.
- Experience with robotics, including adjusting and touching up robot paths in production applications.
- Ability to read, interpret, and design electrical schematics and control diagrams.
- Proficiency with Microsoft Word, Excel, Project, and PowerPoint for documentation, reporting, and project management.
- Experience using AutoCAD or AutoCAD Electrical for control panel and system design.
- Strong understanding of controls engineering principles, including PLCs, HMIs, vision systems, and industrial networking.
- Effective communication and collaboration skills to work with cross-functional teams including maintenance, production, and engineering.
Additional Skills & Qualifications
- Experience working in automotive or high-volume manufacturing environments.
- Familiarity with typical automation equipment such as conveyors, robots, sensors, and error-proofing devices.
- Exposure to both manual and automated assembly operations and the ability to recommend automation opportunities.
- Experience coordinating with external automation and capital equipment vendors for new installations and upgrades.
- Ability to develop and document standard work, operating procedures, and maintenance instructions for controls systems.
- Strong organizational skills to manage multiple projects, tight deadlines, and shifting priorities in a fast-paced environment.
- Continuous improvement mindset with a focus on cost reduction, efficiency, and reliability enhancements.
- Comfort working on the production floor and responding quickly to equipment issues.
- Capability to train and coach maintenance personnel on new systems, programming changes, and troubleshooting techniques.
Work Environment
The role is based in a typical automotive manufacturing plant that operates in a fast-paced, on-the-floor environment with tight deadlines and occasional high-pressure situations. The facility is a union environment with a collaborative and laid-back culture. The Controls Engineer works closely with a team of other controls engineers, controls technicians, maintenance personnel, and production staff. Work involves frequent presence on the production floor around automated equipment, robots, and assembly systems. The position uses a range of technologies and tools, including Allen-Bradley PLCs, Studio 5000 Logix Designer, FactoryTalk View Studio, Cognex and Keyence vision systems, AutoCAD or AutoCAD Electrical, and standard Microsoft Office applications. Typical attire follows automotive plant standards, such as jeans or slacks paired with a polo or button-down shirt. Shift options include a B shift from Tuesday to Friday, 5:30 p.m. to 4:00 a.m., and a day shift from Monday to Thursday, 6:00 a.m. to 4:30 p.m., depending on operational needs.
Job Type & Location
This is a Permanent position based out of Kansas City, MO.
Pay and Benefits
The pay range for this position is $80000.00 - $105000.00/yr. Individual compensation offered for this position within this range will depend on many factors, including qualifications, skills, relevant experience, job knowledge, geographic location, internal equity, and other pertinent job-related factors. Company provided medical, dental, vision benefits
HSA, EAP
Sponsorship opportunities
Workplace Type
This is a fully onsite position in Kansas City,MO.
Application Deadline
This position is anticipated to close on Oct 13, 2026. About Actalent

Actalent is a global leader in engineering and sciences services and talent solutions. We help visionary companies advance their engineering and science initiatives through access to specialized experts who drive scale, innovation and speed to market. With a network of almost 20,000 consultants and 5,000 clients across the U.S., Canada, Asia and Europe, Actalent serves many of the Fortune 500. We are proud to be an Engineering News-Record (ENR) Top 500 Design Firm for our engineering design services and a ClearlyRated Best of Staffing® winner for both client and talent service.

The company is an equal opportunity employer and will consider all applications without
regard to race, sex, age, color, religion, national origin, veteran status, disability,
sexual orientation, gender identity, genetic information or any characteristic protected
by law.

If you would like to request a reasonable accommodation, such as the modification or
adjustment of the job application process or interviewing process due to a disability,
please email [email protected] for other accommodation options.

San Francisco Fair Chance Ordinance:
Pursuant to the San Francisco Fair Chance Ordinance, for all positions located in the
city and county of San Francisco, we will consider for employment qualified applicants
with arrest and conviction records.

Massachusetts Lie Detector:
It is unlawful in Massachusetts to require or administer a lie detector test as a
condition of employment or continued employment. An employer who violates this law
shall be subject to criminal penalties and civil liability.

Use of Artificial Intelligence (AI):
We may use Artificial Intelligence (AI) to support parts of our hiring process,
including sourcing, screening, and evaluating candidates. AI helps assess applications
and qualifications, but final decisions are made by our hiring team. By applying, you
acknowledge and agree that your application may be reviewed using AI tools.