The Role

The Senior Controls Engineer is responsible for providing advanced controls engineering and technical oversight within a vehicle assembly manufacturing environment. This role exercises a high degree of independent judgment, strategic thinking, and technical authority to support plant performance, safety, quality, cost, and throughput objectives . This role drives capital projects, continuous improvement initiatives, and new model launch while ensuring long-term reliability and cost-effective maintenance of plant systems.

What You’ll Do

• Lead controls engineering strategy and execution for manufacturing systems within a vehicle assembly facility.

• Serve as the technical authority for PLC, robotics, and network architecture standards.

• Manage and execute complex electrical and controls projects including new installations, major upgrades, model change activities, throughput improvements, and lifecycle replacements.

• Develop and approve cost estimates, investment forecasts, business cases, and appropriation requests for capital projects.

• Provide technical mentorship to Controls Engineers, Automation Engineers, and Skilled Trades across multiple shifts.

• Lead root cause analysis and resolution of complex equipment and system failures.

• Drive continuous improvement initiatives utilizing statistical methods and data-driven decision making.

• Coordinate with Manufacturing Engineering, corporate engineering organizations, and suppliers on new model planning, CQPI, sourcing, and equipment validation.

• Establish and manage project support plans between plant operations, corporate engineering, and contractor resources.

• Represent Engineering in plant leadership meetings and cross-functional business planning activities.

• Influence plant-wide goals through Business Plan Deployment and cross-functional alignment.

• Support implementation of GMS and Quality Network initiatives to improve operational excellence.

• Oversee development and adherence to engineering standards, documentation, and best practices.

• Develop and monitor project schedules, risk mitigation plans, and execution timelines.

• Provide input into plant capital planning and Central Manufacturing Engineering budgets.

• Ensure long-term reliability, maintainability, and cost efficiency of manufacturing equipment and infrastructure.

• Drive energy efficiency, operational cost reduction, and maximum throughput strategies.

• Partner with Plant Training teams to develop and deploy training for new technologies introduced to the facility.

• Champion safety as the highest priority, enforcing safe work practices and driving improvements in ergonomics, health, safety, and housekeeping.

• Maintain strong working relationships with hourly employees, union leadership, plant management, suppliers, and external support organizations.
  

Your Skills and Abilities (Required Qualifications)

• Advanced ability to program, optimize , and troubleshoot Rockwell / Allen-Bradley ControlLogix platforms.

• Advanced troubleshooting and programming experience with FANUC robotics.

• Expert-level ability to read, interpret, and modify electrical schematics and controls documentation.

• Strong expertise in troubleshooting complex automated manufacturing systems.

• Advanced knowledge of industrial networks ( DeviceNet , ControlNet, Ethernet/IP).

• Demonstrated ability to lead complex problem resolution where problems are unusual, ambiguous, and high-impact .

• High level of analytical capability and structured problem-solving skills.

• Strong leadership, interpersonal, and communication skills (oral and written).

• Willingness to work any shift and support off-shift production, shutdowns, and launch activities.

• Willingness to support weekend or extended hours during critical production and project phases.

Preferred Qualifications

• Significant experience of 5+ years in automotive vehicle assembly manufacturing.

• Experience leading automation strategy or large capital projects.

• Bachelor’s Degree in Electrical Engineering or equivalent technical experience.

• Experience with manufacturing software integration (MES, SCADA, data acquisition systems).

• Demonstrated mentoring or supervisory experience over engineering or technical teams.