Controls Engineer

POSITION SUMMARY

Provide the necessary Controls and Welding Engineering skills to assure the successful implementation of new assembly tools and equipment. Support, maintain, and improve existing assembly automation equipment. Manage engineering changes, and meet all customer’s quality, engineering, and delivery requirements.

SUMMARY OF RESPONSIBILITIES

·         Analyze, troubleshoot, and modify Allen Bradley platform PLC logic.

·         Modify Robotic position, code, data, parameters and I/O (ABB,Fanuc).

·         Setup, and maintain control parameters for GMAW and resistance welding (WTC,Bosch,Lincoln, Fronius).

·         Participate in weekly tech reviews with the project team.

·         Support the assembly process meetings at the integrator, and communicate the assembly equipment status, and tooling timing charts.

·         Support all customer meetings, internal meetings, and project reviews.

·         Interface with all internal departments to ensure they are kept up to date on the assembly equipment, tool status, and the timely tryouts and launch of the equipment in the business unit.

·         Assist the team in all launch and production start up activities.

·         Support all assembly engineering changes.

·         Support project engineering on new and existing programs.

·         Assist in the integration, start-up and debug of plant floor welding equipment.

·         Train, coach and mentor the welding process for quality, manufacturing, and skilled trades colleagues.

·         Direct and/or participate in root cause analysis and team problem solving activities (ex. 8D reports, department meetings, etc.).

·         Communicate internally to coordinate and implement product and process engineering changes.

·         Work independently or as part of a cross functional team to troubleshoot and effectively solve manufacturing line issues.

·         Write procedures and work instructions as required.

·         Support APQP and procedures.

·         Ensure the assembly equipment and tool program is following proper Tower procedures and standards.

·         Maintain a positive working relationship with all levels of the organization.

·         Maintain high standards of housekeeping throughout the work area.

·         Assure compliance with federal, state, local and corporate policies, regulations and laws.

·         Adhere to Company policies and procedures (e.g., Finance Manual, Colleague Handbook, Change Control, etc.).

RELATIONSHIPS/CONTACTS

Reports directly to the Manager Engineering/Engineering Supervisor. Interfaces on a frequent basis with Operations, Materials, Jig & Fixture, Maintenance, Quality, and corporate Engineering. Interfaces on an as needed basis with HR, IT, Purchasing, and Finance.

LEADERSHIP/SUPERVISORY RESPONSIBILITIES

·         Ability to coach operations and train maintenance support teams.

·         Provides model behavior to demonstrate corporate values

MINIMUM QUALIFICATIONS

·         Bachelors Degree in Engineering or equivalent experience

·         Experience in metal joining

·         Working knowledge of welding processes

·         Experienced in PLC and HMI programming, preferably Allen Bradley platforms

·         Knowledge in robotic programming (ex. ABB, Fanuc robots, etc.)

·         Understanding of electrical/controls circuitry and schematics.

·         Knowledge of AutoCAD and weld drawings

·         Knowledge of manufacturing processes, product designs, safety, quality and workflow

·         Minimum six (6) years of manufacturing experience (with working knowledge of welding, assembly, automation, tooling, and related processes) and / or training or equivalent combination of education and experience.

·         Ability to problem solve and work with mathematical concepts such as probability and statistical inference, and fundamentals of plane and solid geometry. 

·         Proven knowledge in the Production Part Approval Process (PPAP)

·         Ability to mentor and teach the team in effective problem solving methods.

·         Experience in applying and teaching lean manufacturing concepts.

·         Experience in design, fabrication, and installation of assembly equipment and tools

·         Sound organization skills. 

·         Computer literacy and good knowledge of Microsoft Office software.

·         Good communicator with the ability to lead team meetings

·         Ability to lead the assembly equipment and tool projects including the interface with the customer, assembly integrator shops, and the project team

·         Knowledge of APQP processes and the ability to manage and maintain standardized procedures

·         Ability to visualize and comprehend all aspects of a manufacturing equipment and tooling, understand the relationships of factors affecting a given situation, be attentive to detail, and continually seek to improve work processes. Knowledge of automated processes including mechanical, electrical, pneumatic, hydraulic and control systems and how they interact with each other.

·         Working knowledge of: continuous improvement, project management, facility engineering, process engineering, product engineering, equipment technology/capabilities, plant capacity and general problem solving.

·         Ability to read and interpret CMM data, SPC and dimensional data reports.

·         Excellent organizational, analytical, team building and communication skills

·         Ability to read and write in English.