Controls Engineer

Position Summary: Develop and support automation and control systems. Support day to day troubleshooting and problem-solving activities. Conduct all engineering analysis necessary to support continuous improvement in operating performance, process flow, productivity, and operational expansion – and lead the implementation of the resultant action plan. Develop and support automation and control systems. Support day to day troubleshooting and problem-solving activities.

Job Purpose: A key role in the team effort to improve operational performance and grow the business. Provide the data, analysis and recommendations necessary for managerial decision making. Play a key role in developing and building new manufacturing cells, supporting and improving existing cells and equipment.

Reporting: Directly to the Director of Manufacturing

Responsibilities:

• Develop and implement automated manufacturing cells and systems for sheet metal stamping, weld assembly operations, and material handling/conveyance systems

• PLC and HMI programming

• Design and build control panels, generating necessary layouts and electrical drawings

• Install, program, and commission robot arms such as Kuka, ABB, and Fanuc

• Design and build robotic end of arm tools for material handling, welding, and dispensing operations

• Provide on-site and remote support for control systems and automated equipment

• Troubleshoot root cause of malfunctions, electrical, mechanical, and/or software

• Identify opportunities for improvements in productivity, equipment reliability, and safety

• Participate in new/used equipment/tool purchase and commissioning projects

• Participate in special projects

• Understands and complies with EMS policy, objectives, and procedures.

• Lead the training and implementation of Lean Manufacturing methodologies (including 5S, standardized work, process flow analysis, material delivery, etc.).

• Identify immediate opportunities for productivity improvement in assembly and weld operations, and actively participate/lead the implementation of the necessary changes.

• Develop appropriate metrics to determine OEE (overall equipment effectiveness) and lead the efforts to improve capacity utilization.

• Provide the Industrial Engineering support necessary to optimize inventory management.

• Develop layouts and process flow analysis to support plant rearrangement and expansion.

• Conduct special studies to assist in decision making relative to new business opportunities and/or new equipment purchases.

• Initiate process design and development with all new programs. (IATF requirement 5.3.1 – re-assign responsibility if moving)

• Understands and complies with EMS policy, objectives, and procedures.

EMST Member:

• Assumes the responsibility to review and update all NCS EMS policies and procedures. Assures all NCS employees are aware of, and compliant with the EMS policy, objectives, aspects & impacts, and compliance obligations.

Experience:

• Minimum of five years’ experience in a similar automation or controls engineering role

• A proven track record relative to successful implementation of automation and robotic manufacturing systems

• Metal stamping/assembly processes.

• High mix, low volume manufacturing experience.

• Ability to work with limited supervision.

• Familiarity and experience with Allen Bradley control systems.

• Familiarity with Kuka, ABB, and Fanuc robots.

• Excellent organizational skills and interpersonal skills.

• Must be able to both ‘do and lead’.

• Minimum of five years’ experience in a similar automation or controls role

• A proven track record relative to successful implementation of automation and robotic manufacturing systems

• Metal stamping/assembly processes.

Education:

• Technical degree, with Industrial or Manufacturing Engineering required.